Renr9579 13 00 All

RENR9579-13
January 2012
Disassembly and
Assembly
C9 Engines for Caterpillar Built
Machines
TXD1-Up (Engine)
THX1-Up (Engine)
THY1-Up (Engine)
SAFETY.CAT.COM
i03991620
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts or parts with equivalent speci-
fications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
RENR9579-13 3
Engine Book
Table of Contents
Table of Contents Camshaft - Remove .............................................. 55

Camshaft - Install .................................................. 56
Camshaft Gear - Remove and Install .................. 57
Camshaft Bearings - Remove ............................... 57
Disassembly and Assembly Section Camshaft Bearings - Install ................................... 58
Engine Oil Pan - Remove and Install ................... 59
Fuel Filter Base - Remove and Install .................... 4
Cylinder Liner - Remove ....................................... 60
Fuel Transfer Pump - Remove and Install ............. 5
Cylinder Liner - Install ........................................... 61
Unit Injector - Remove ............................................ 7
Piston Cooling Jets - Remove and Install ............. 61
Unit Injector - Install ................................................ 8
Pistons and Connecting Rods - Remove .............. 62
Unit Injector Sleeve - Remove .............................. 10
Pistons and Connecting Rods - Disassemble ....... 63
Unit Injector Sleeve - Install ................................... 11
Pistons and Connecting Rods - Assemble ........... 64
Unit Injector Hydraulic Pump - Remove ................ 12
Pistons and Connecting Rods - Install .................. 65
Unit Injector Hydraulic Pump - Install .................... 13
Connecting Rod Bearings - Remove .................... 66
Turbocharger - Remove ........................................ 14
Connecting Rod Bearings - Install ........................ 67
Turbocharger - Install ............................................ 14
Crankshaft Main Bearings - Remove .................... 68
Exhaust Manifold - Remove and Install ............... 15
Crankshaft Main Bearings - Install ........................ 69
Air Inlet Heater - Remove ..................................... 16
Crankshaft - Remove ............................................ 69
Air Inlet Heater - Install ......................................... 17
Crankshaft - Install ................................................ 70
Inlet and Exhaust Valves - Remove and Install .... 18
Bearing Clearance - Check ................................... 71
Inlet and Exhaust Valve Guides - Remove and
Atmospheric Pressure Sensor - Remove and
Install ................................................................... 19
Install ................................................................... 72
Inlet and Exhaust Valve Seat Inserts - Remove and
Coolant Temperature Sensor - Remove and
Install ................................................................... 20
Install ................................................................... 73
Engine Oil Filter Base and Oil Cooler - Remove .. 21
Engine Oil Pressure Sensor - Remove and Install
Engine Oil Filter Base - Disassemble ................... 22
............................................................................. 74
Engine Oil Filter Base - Assemble ........................ 23
Injection Actuation Pressure Sensor - Remove and
Engine Oil Filter Base and Oil Cooler - Install ..... 23
Install ................................................................... 75
Engine Oil Pump - Remove .................................. 24
Speed/Timing Sensor - Remove and Install ........ 76
Engine Oil Pump - Install ...................................... 25
Turbocharger Outlet Pressure Sensor - Remove and
Water Pump - Remove ......................................... 27
Install ................................................................... 77
Water Pump - Disassemble ................................. 27
Inlet Air Temperature Sensor - Remove and
Water Pump - Assemble ...................................... 28
Install ................................................................... 78
Water Pump - Install ............................................. 29
Fan Drive - Remove ............................................. 78
Water Temperature Regulator - Remove and Install
Fan Drive - Disassemble ..................................... 79
............................................................................. 29
Fan Drive - Assemble .......................................... 80
Gear Group (Rear) - Remove and Install .............. 31
Fan Drive - Install .................................................. 81
Flywheel - Remove ............................................... 35
Electronic Control Module - Remove and Install ... 81
Flywheel - Install ................................................... 36
Electric Starting Motor - Remove and Install ....... 82
Crankshaft Rear Seal - Remove ........................... 36
Crankshaft Rear Seal - Install ............................... 37
Flywheel Housing - Remove and Install .............. 38 Index Section
Flywheel Housing - Remove and Install .............. 39
Vibration Damper and Pulley - Remove and Install Index ..................................................................... 83
............................................................................. 40
Crankshaft Front Seal - Remove .......................... 41
Crankshaft Front Seal - Install .............................. 41
Front Cover - Remove .......................................... 42
Front Cover - Install .............................................. 43
Housing (Front) - Remove .................................... 44
Housing (Front) - Install ........................................ 45
Crankcase Breather - Remove and Install ........... 45
Cylinder Block Cover - Remove and Install .......... 46
Valve Mechanism Cover - Remove and Install ..... 48
Valve Mechanism Cover Base - Remove and
Install ................................................................... 48
Rocker Arm and Shaft - Remove .......................... 50
Rocker Arm - Disassemble ................................... 50
Rocker Arm - Assemble ........................................ 51
Rocker Arm and Shaft - Install .............................. 51
Cylinder Head - Remove ...................................... 52
Cylinder Head - Install .......................................... 53
Lifter Group - Remove and Install ......................... 54
4 RENR9579-13
Engine Book
Disassembly and Assembly Section
Disassembly and Assembly

Section
i02293710
Fuel Filter Base - Remove and

Install
SMCS Code: 1262-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
Strap Wrench
A 185-3630 1
Assembly
g01148430
Illustration 1
NOTICE
Keep all parts clean from contaminants. 1. Drain the fuel from fuel filter base (2) into a
suitable container for storage or for disposal.
Contaminants may cause rapid wear and shortened
component life. 2. Use Tooling (A) in order to remove fuel filter (1).
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and

mandates.
Note: Plug all hose assemblies and all tube

assemblies. This helps to prevent fluid loss, and this
helps to keep contaminants from entering the system.
g01148847
Illustration 2
3. Disconnect tube assemblies (4) and (5).
4. Disconnect harness assemblies (6) and (7).
5. Remove bolts (3) and remove fuel filter base (2).

RENR9579-13 5
Engine Book
Installation Procedure i03012021
Fuel Transfer Pump - Remove

and Install
SMCS Code: 1256-010
Removal Procedure
Table 2
Required Tools
A(1) 218-8171 Bolt 1
(1) Part of 218-8172 Fuel Transfer Pump and Mounting Gp
Start By:
a. Remove the unit injector hydraulic pump. Refer

to Disassembly and Assembly, “Unit Injector
Hydraulic Pump - Remove”.
g01148847
Illustration 3
NOTICE
1. Position fuel filter base (2) onto the engine. Install Care must be taken to ensure that fluids are contained
bolts (3). during performance of inspection, maintenance, test-
2. Connect harness assemblies (6) and (7). collect the fluid with suitable containers before open-
3. Connect tube assemblies (4) and (5). nent containing fluids.

Dealer Service Tool Catalog” for tools and supplies
products.

mandates.
NOTICE
Keep all parts clean from contaminants.

component life.
Note: Tooling (A) is required for replacement of the

fuel transfer pump.
g01148430
Illustration 4
4. Install fuel filter (1) onto fuel filter base (2).

Prime the fuel system. Refer to Operation and
Maintenance Manual, “Fuel System - Prime” for
more information.
6 RENR9579-13
Engine Book
NOTICE

component life.
1. Thoroughly clean the components and the mating

surfaces.
g01525049
Illustration 5
1. Disconnect tube assemblies (1).
2. Remove bolt (3) that is located at the top left

corner of fuel transfer pump (5) first.
3. Install Tooling (A) in the top left corner of the pump.

Tighten Tooling (A) to a torque of 10 N·m (89 lb in).
g01525049
4. Remove bolts (2) that fasten fuel transfer pump Illustration 6
(5) to the unit injector hydraulic pump.
2. Install O-ring seal (4).
Note: Do not apply excessive torque to the bolt.
3. Position fuel transfer pump (5) on the unit injector
Note: Tooling (A) has an undersized bolt head. hydraulic pump. Be sure to align the drive tang of
Tooling (A) must be installed in order to prevent the fuel transfer pump to the drive slot in the end
the body of the unit injector hydraulic pump from of the pump shaft.
separating during service.
4. Install bolts (3). Lightly tighten the bolts at this
5. Remove remaining bolts (3) from fuel transfer time.
pump (5).
5. Install bolts (2) for fuel transfer pump (5). Lightly
6. Separate fuel transfer pump (5) from the unit tighten the bolts at this time.
injector hydraulic pump.
6. Remove Tooling (A) and install bolt (3). Lightly
7. Remove O-ring seal (4). tighten the bolt at this time.
7. Tighten bolts (3) evenly to a torque of 28 ± 2 N·m

Installation Procedure (21 ± 1 lb ft).
Table 3
8. Tighten bolts (3) again to a torque of 28 ± 2 N·m
Required Tools (21 ± 1 lb ft).
Part
Tool Number Part Description Qty 9. Tighten bolts (2) to a torque of 8.0 ± 0.4 N·m
(71 ± 4 lb in).
A(1) 218-8171 Bolt 1
(1) Part of 218-8172 Fuel Transfer Pump and Mounting Gp End By:
a. Install the unit injector hydraulic pump. Refer

Hydraulic Pump - Install”.
RENR9579-13 7
Engine Book
i02877582
Unit Injector - Remove

SMCS Code: 1290-011
Removal Procedure
Table 4
Required Tools
Fuel Injector Installer
A 152-1057 1
As
B 191-6077 Bracket 1
C 274-9198 Leg 2
Start By:
a. Remove the valve mechanism cover. Refer to g01148880

Illustration 7
Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.
2. Use a small flat head screwdriver to disconnect
harness assembly (2) from unit injector (1).
NOTICE
Care must be taken to ensure that fluids are contained 3. Remove socket head bolts (3).

products.

mandates.
NOTICE

component life.
1. Remove the plug at the rear of the cylinder head. g01160779

Illustration 8
Allow the engine oil to drain from the hole in the
cylinder head before the unit injector is removed.
4. Attach Tooling (B) to the rocker shaft and Tooling
(A). Attach Tooling (C) onto the unit injector and
Tooling (A). Carefully remove unit injector (1) from
the cylinder head.
Note: Do not use a wire brush on the tip of the unit

injector. Damage to the unit injector will occur.
8 RENR9579-13
Engine Book
i03868850
Unit Injector - Install

SMCS Code: 1290-012
Installation Procedure
Table 5
Required Tools
A 152-1057 Fuel Injector Installer As 1
B 191-6077 Bracket 1
D 272-1149 Leg 2
E 149-2955 Seal Protector 1
F 149-2956 Seal Installer 1
1U-5718 Vacuum Pump 1
169-7372 Bottle Assembly 1
G Clear Plastic Tubing

4C-4057 1
7.92 mm (0.312 inch) OD
Clear Plastic Tubing
4C-4055 1
6.35 mm (0.250 inch) OD
g01137291 H 9U-5470 Reamer 1
Illustration 9
J 4C-6161 Tube Brush 1

5. Remove O-ring seals (6), (7), and (8) from unit
injector (1). Remove backup rings (4), (5), and (9) K 9U-6862 Tapered Brush 1
from unit injector (1). L 4C-6774 Vacuum Gun Kit 1
M 4C-5027 Tap Wrench 1
NOTICE

component life.
1. Evacuate as much fuel and oil as possible from

the cylinder head before installing the unit injector.
Several evacuations may be necessary. Use
Tooling (G) to remove the fuel and oil from the
cylinder head.
Note: Tooling (L) is available to clean loose material

from the sleeve bore and the cylinder.
2. Inspect the unit injector sleeve for damage and

carbon deposits.
RENR9579-13 9
Engine Book
3. Clean the carbon from the sleeve, the sleeve bore

and the end of the unit injector, if the unit injector
is being reused. Clean the carbon from the seat
area that is inside of the cylinder head. A fine
grade of Scotch Brite material is preferred. Use
Tooling (H) to clean the bore of the unit injector tip.
Use the Surface Reconditioning Pad in order to
clean the carbon in the cylinder head. Use Tooling
(J) in order to remove the carbon from the surface
of the sleeve.
Note: Using power tools in order to rotate the material

should not be necessary. The carbon in the sleeve is
more removable than the carbon at locations that are
exposed to higher temperatures.
The following procedure is the preferred method

of cleaning the sleeve bore.
Place a 38 mm (1.5 inch) square piece of Scotch

Brite material on the end of Tooling (K). Twist
Tooling (K) with Tooling (M) against the lower
surface of the sleeve bore.
The surface should be cleaned until the surface is

smooth and shiny. The entire sleeve bore should
be cleaned in order to remove any loose carbon
particles.
g01137291
Illustration 10
Note: Tooling (J) is available to clean loose material
from the sleeve bore and the cylinder. 4. Lubricate O-ring seals (6), (7), and (8) and the
sleeve bore of the unit injector sparingly with clean
engine oil.
NOTICE
The correct procedures and tooling specifications 5. Use Tooling (E) and Tooling (F) to install the
must always be used. Failure to follow any of the backup rings (4) and (5) first. Install O-ring seal
procedures may result in damage, malfunction, or (6).
possible engine failure.
6. Use Tooling (E) and Tooling (F) to install backup
Note: New seals should be installed after each ring (9). Install O-ring seal (8).
removal of the unit injector from the engine. To order
O-ring seals for the unit injector, refer to the Parts 7. Install O-ring seal (7).
Manual.
8. Lubricate the O-ring seals and the backup rings
NOTICE on unit injector (1) with clean engine oil before
The O-ring seals and the backup rings must be in- installation.
stalled in the correct orientation. Damaged seals will
result in excessive oil consumption or excessive leak- Note: Proper installation of the unit injector is very
age under the valve cover. Use care to prevent nicks important. Damage to the upper high pressure seals
or damage to the seals. can cause excessive oil leakage under the valve
cover. This may cause the engine not to start due
to a low actuation pressure. Damage to the lower
high pressure seals may allow high pressure oil to
leak into the fuel supply passage. This will result in
excessive oil consumption.
Note: Do not hit or strike the unit injector during

installation. Do not use a wire brush to clean the tip of
the unit injector. Damage to the unit injector will occur.
10 RENR9579-13
Engine Book
9. When you install a new unit injector the E-Trim 11. Install socket head bolt (3) on the exhaust side of
value must be programmed into the Electronic the bracket. Tighten the exhaust side of socket
Control Module. The E-Trim value is a six digit head bolt (3) until the bolt is seated. Tighten the
alphanumeric code that is supplied with the data inlet side of socket head bolt (3) to a torque of
sheet that comes with the new unit injectors. Use 12 ± 1 N·m (106 ± 9 lb in) .
the following menu to program the E-Trim value.
12. Connect harness assembly (2) to unit injector (1).
• ECM Summary Screen
13. Install the plug at the rear of the cylinder head.
• Service Menu
End By:
• Calibration
a. Install the valve mechanism cover. Refer to
• Injector Code Calibration Disassembly and Assembly, “Valve Mechanism
i03476861
Unit Injector Sleeve - Remove

SMCS Code: 1713-011
Removal Procedure
Table 6
Required Tools
Part
Tool Number Part Description Qty
A 1P-3042 Plug Tap 1
B 221-0052 Guide Sleeve 1
9U-6858 Bridge Plate 1
221-9778 Puller Stud 1
g01160812
Illustration 11
C 4K-0367 Full Nut 1
10. Use Tooling (A), Tooling (B) and Tooling (D) to 5P-8247 Hard Washer 1
install unit injector (1) in the cylinder head.
9U-6877 Thrust Bearing 1
D 221-9803 Rubber Stopper 1
Start By:
a. Remove the unit injectors. Refer to Disassembly

and Assembly, “Unit Injector - Remove”.
NOTICE

component life.
g01148880
Illustration 12
RENR9579-13 11
Engine Book
i03742983
NOTICE
Unit Injector Sleeve - Install
ing, adjusting and repair of the product. Be prepared to SMCS Code: 1713-012
ing any compartment or disassembling any compo- Installation Procedure
Table 7
Refer to Special Publication, NENG2500, “Caterpillar Required Tools
suitable to collect and contain fluids on Caterpillar Tool Part Number Part Description Qty
products. E 221-9777 Sleeve Installer 1
Dispose of all fluids according to local regulations and F 4C-5552 Large Bore Brush 1
mandates. G 4C-9507 Retaining Compound 1
1. Drain the coolant from the cooling system into a

NOTICE
suitable container for storage or disposal. Refer
to Operation and Maintenance Manual, “Refill
Capacities and Recommendations”.
component life.
2. Position Tooling (D) at the bottom of the unit
injector sleeve.
1. Thoroughly clean the unit injector sleeves and the
3. Coat Tooling (A) with clean grease. Use Tooling bores for the unit injectors with Tooling (F).
(A) and Tooling (B) to cut threads into the unit
injector sleeve.
g02021929
Illustration 14
g01137445
Illustration 13 2. Apply clean engine oil to O-ring seals (2). Install
O-ring seals (2) on unit injector sleeve (1).
4. Install Tooling (C) in unit injector sleeve (1).
3. Position unit injector sleeve (1) on Tooling (E).
5. Remove unit injector sleeve (1). Remove the
O-ring seals. 4. Apply a thin coating of Tooling (G) around the
outer circumference of unit injector sleeve (1) at
Area (C).
5. Position unit injector sleeve (1) in the cylinder

head. Use a hammer to install unit injector sleeve
(1) in the cylinder head.
12 RENR9579-13
Engine Book
Note: Allow Tooling (G) to cure for two hours at 21 °C

(70 °F) before filling the engine with fuel or coolant.
Longer curing time is required for lower temperatures.
6. Fill the cooling system with coolant to the correct

level. Refer to Operation and Maintenance Manual,
“Refill Capacities and Recommendations”.
End By:
a. Install the unit injectors. Refer to Disassembly and

Assembly, “Unit Injector - Install”.
i02538215
Unit Injector Hydraulic Pump -

Remove
SMCS Code: 1714-011
Removal Procedure Illustration 15

g01150290
NOTICE 1. Disconnect tube assemblies (3), (4), and (5).

2. Disconnect hose assembly (6).
component life. 3. Disconnect harness assembly (2) from unit
injector hydraulic pump (1).
NOTICE

products.

mandates.
g01270628
Illustration 16
4. Support unit injector hydraulic pump (1) by hand

and remove bolts (7). Remove unit injector
hydraulic pump (1).
RENR9579-13 13
Engine Book
g01150295 g01150295
Illustration 17 Illustration 18
5. Remove nut (10), washer (9), and gear (8). 1. Install gear (8), washer (9), and nut (10) on unit
Remove O-ring seal (11) from unit injector injector hydraulic pump (1). Tighten nut (10) to a
hydraulic pump (1). torque of 65 ± 3 N·m (48 ± 2 lb ft). Replace O-ring
seal (11).
i02538297
Unit Injector Hydraulic Pump

- Install
SMCS Code: 1714-012
NOTICE

component life.
NOTICE
collect the fluid with suitable containers before open- g01270628
Illustration 19
nent containing fluids. 2. Position unit injector hydraulic pump (1) in the
front housing.
Dealer Service Tool Catalog” for tools and supplies 3. Support unit injector hydraulic pump (1) and install
suitable to collect and contain fluids on Caterpillar bolts (7).
products.

mandates.
14 RENR9579-13
Engine Book
g01150290 g01150421
4. Connect hose assembly (6). 1. Disconnect hose assembly (1).
5. Connect tube assemblies (3), (4), and (5). 2. Remove bolts (4) and tube assembly (5).
6. Connect harness assembly (2) to unit injector 3. Attach a suitable lifting device onto turbocharger
hydraulic pump (1). (2). The weight of turbocharger (2) is
approximately 27 kg (60 lb). Remove nuts (3).
Remove turbocharger (2) and the gasket.
i02297056
Turbocharger - Remove i04000968
SMCS Code: 1052-011 Turbocharger - Install

Removal Procedure SMCS Code: 1052-012
NOTICE Installation Procedure

Table 8
Contaminants may cause rapid wear and shortened Required Tools

component life.
Part
NOTICE A 5P-3931 Anti-Seize Compound -
ing, adjusting and repair of the product. Be prepared to NOTICE
collect the fluid with suitable containers before open- Keep all parts clean from contaminants.
nent containing fluids. Contaminants may cause rapid wear and shortened
component life.
Tools and Shop Products Guide” for tools and supplies 1. Apply Tooling (A) to the turbocharger mounting
suitable to collect and contain fluids on Caterpillar studs on the exhaust manifold.
products.

mandates.
RENR9579-13 15
Engine Book
g01150421 g00949916
Typical Example
2. Attach a suitable lifting device to turbocharger (2).
The weight of turbocharger (2) is approximately 1. Remove nuts (2), the washers, and the spacers
27 kg (60 lb). Position the gasket and turbocharger from studs (1).
(2) on the exhaust manifold.
2. Remove the exhaust manifold assembly and the
Note: Discard the nuts after use. Use new nuts for gaskets from the cylinder head assembly.
installation.
3. Disassemble the exhaust manifold assembly into
3. Install nuts (3). Tighten nuts (3) to a torque of three pieces (3), (4), and (5).
54 ± 5 N·m (40 ± 4 lb ft).
4. Position tube assembly (5) and install bolts (4). Installation Procedure
5. Connect hose assembly (1). NOTICE
i04000972 Contaminants may cause rapid wear and shortened
component life.
Exhaust Manifold - Remove
and Install
SMCS Code: 1059-010
Removal Procedure
Start By:
a. Remove the turbocharger. Refer to Disassembly

and Assembly, “Turbocharger - Remove”.
NOTICE

component life.
16 RENR9579-13
Engine Book
End By:
a. Install the turbocharger. Refer to Disassembly and

Assembly, “Turbocharger - Install”.
i02312489
Air Inlet Heater - Remove

SMCS Code: 1090-011
Removal Procedure
NOTICE

component life.
g00988420
Illustration 24
Typical Example
1. Check the condition of studs (1). Replace studs

(1), if necessary.
g01158011
Illustration 26
1. Disconnect cable assembly (1).
2. Disconnect harness assembly (2).
3. Remove bolt (4) and disconnect ground strap (3).

g00949916
Illustration 25
Typical Example 4. Remove remaining bolts (4) and remove air inlet
elbow (5).
Note: Discard the nuts after use. Use new nuts for
installation.
2. Install the new gaskets with the tabs upward.

Assemble three pieces (3), (4), and (5) into the
exhaust manifold assembly. Position the gaskets
and the exhaust manifold assembly on the cylinder
head assembly. Install the spacers, the washers,
and nuts (2).
3. Tighten nuts (2) to a torque of 55 ± 10 N·m

(41 ± 7 lb ft).
RENR9579-13 17
Engine Book
NOTICE

products.

mandates.
g01158012
Illustration 27
5. Remove air inlet heater (6).
i02319594
Air Inlet Heater - Install

SMCS Code: 1090-012
Table 9
Required Tools
Part
Tool Part Description Qty
Number Illustration 28
g01158012
A 4C-9500 Quick Cure Primer 1

1. Clean the face of air inlet heater (6) with cleaning
B 8C-8422 Sealant 1 solvent. Apply Tooling (A) to the face of air inlet
heater (6). Allow Tooling (A) to dry for 3 to 5
minutes. Apply Tooling (B) to the joint face and
NOTICE
spread uniformly. Air inlet heater (6) must be
installed and tightened within 10 minutes.
component life.
18 RENR9579-13
Engine Book
The valve spring keepers can be thrown from

the valve when the valve spring compressor is
released. Ensure that the valve spring keepers
are properly installed on the valve stem. To help
prevent personal injury, keep away from the front
of the valve spring keepers and valve springs
during the installation of the valves.
g01158011
Illustration 29
2. Position air inlet elbow (5). Install bolts (4).
3. Connect ground strap (3) and install bolt (4).
4. Connect harness assembly (2).
5. Connect cable assembly (1).

g01137560
Illustration 30
i02550198
Inlet and Exhaust Valves -

Remove and Install Personal injury can result from being struck by
SMCS Code: 1105-010 parts propelled by a released spring force.
Make sure to wear all necessary protective equip-

Removal Procedure ment.
Table 10 Follow the recommended procedure and use all
Required Tools recommended tooling to release the spring force.
Part
Tool Number Part Description Qty 1. Use Tooling (A) to compress valve springs (3).
5S-1330
Remove retainer locks (1).
A Valve Spring Compressor 1
2. Remove Tooling (A). Remove spring retainer (2)
Start By: and valve springs (3).
a. Remove the cylinder head. Refer to Disassembly 3. Remove valve stem seal (4), spring seat washer
and Assembly, “Cylinder Head - Remove”. (5), and valves (6).
NOTICE Installation Procedure

Table 11
Contaminants may cause rapid wear and shortened Required Tools
component life.
Part
A 5S-1330 Valve Spring Compressor 1
RENR9579-13 19
Engine Book
End By:
NOTICE
Keep all parts clean from contaminants. a. Install the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Install”.
component life.
i02843522
Inlet and Exhaust Valve Guides

- Remove and Install
SMCS Code: 1104-010
Removal Procedure
Table 12
Required Tools
Part
9U-6895
A or Valve Guide Driver 1
4C-6366(1)
(1) If necessary, use Tooling on inlet valve guides.
Start By:
Illustration 31
g01137560 a. Remove the inlet and exhaust valves. Refer to
Disassembly and Assembly, “Inlet and Exhaust
Valves - Remove and Install”.
NOTICE
Improper assembly of parts that are spring loaded Keep all parts clean from contaminants.
can cause bodily injury.
To prevent possible injury, follow the established component life.
assembly procedure and wear protective equip-
ment.
1. Lubricate valves (6) with clean engine oil. Install

valves (6) in the cylinder head assembly. Install
new valve stem seal (4) against the valve guide.
2. Install spring seat washer (5), valve springs (3),

and spring retainer (2).
The valve spring keepers can be thrown from

the valve when the valve spring compressor is
released. Ensure that the valve spring keepers g01137612
Illustration 32
are properly installed on the valve stem. To help
prevent personal injury, keep away from the front
of the valve spring keepers and valve springs 1. Use Tooling (A) to remove the inlet valve guides
during the installation of the valves. and exhaust valve guides from the cylinder head
assembly.
Note: A small amount of grease can be used to hold

the valve keepers in position during installation.
3. Use Tooling (A) to compress valve springs (3).

Install retainer locks (1).
20 RENR9579-13
Engine Book
Table 13 Inlet and Exhaust Valve Seat

Required Tools Inserts - Remove and Install
Part
Tool Number Part Description Qty SMCS Code: 1103-010
9U-6895
A or Valve Guide Driver 1 Removal Procedure
4C-6366(1)
Table 14
B 173-5524 Guide Collar 1
Required Tools
(1) If necessary, use Tooling on inlet valve guides.
Part
NOTICE
Keep all parts clean from contaminants. A 9S-3095 Puller Handle 1
6V-4194(1) Valve Seat Extractor 1
Contaminants may cause rapid wear and shortened B
component life. 1U-9167(2) Valve Seat Extractor 1
(1) For use with Exhaust Valve Seat
(2) For use with Intake Valve Seat
Start By:
a. Remove inlet and exhaust valves. Refer to

g01160500
Illustration 33
1. Position the inlet valve guide and exhaust valve

guide in the cylinder head. Tap on the top of the
valve guides. This is done in order to start the inlet
valve guides and exhaust valve guides into the
cylinder head assembly.
g01137634
Illustration 34
2. Use Tooling (A) and Tooling (B) to install the inlet
valve guide and the exhaust valve guide. Install the 1. Use Tooling (A) and Tooling (B) to remove valve
valve guides until the protrusion is Distance (X). seat inserts (1).
Distance (X) is 12.0 ± 0.5 mm (0.47 ± 0.02 inch)
above the cylinder head assembly.
End By:
a. Install the inlet and exhaust valves. Refer to

RENR9579-13 21
Engine Book
Table 15 Engine Oil Filter Base and Oil

Required Tools Cooler - Remove
Part
Tool Number Part Description Qty SMCS Code: 1306-011; 1378-012
4C-6372(1) Valve Seat Driver 1

C Removal Procedure
364-4009(2) Valve Seat Driver 1
(1)
Table 16
For use with Exhaust Valve Seat
(2) For use with Intake Valve Seat Required Tools
NOTICE
Keep all parts clean from contaminants. Strap Wrench
A 185-3630 1
Assembly
component life. NOTICE

component life.
NOTICE

products.

mandates.
g01137637
Illustration 35
Note: Do not machine the prefinished valve seat

inserts in order to correct the valve stem projection.
An excessive valve stem projection indicates that the
valve seat insert is not seated or material was not
cleaned from the bottom of the counterbore.
1. Lower the temperature of new valve seat inserts

(1). Use Tooling (C) to install valve seat inserts (1)
into the cylinder head.
End By:
a. Install the inlet and exhaust valves. Refer to

g01150737
Illustration 36
22 RENR9579-13
Engine Book
1. Use Tooling (A) to remove engine oil filter (1). i02298275
Engine Oil Filter Base -

Disassemble
SMCS Code: 1306-015
Disassembly Procedure
Start By:
a. Remove the engine oil filter base. Refer to

Disassembly and Assembly, “Engine Oil Filter
Base and Oil Cooler - Remove”.
NOTICE

component life.
g01150959
Illustration 37
2. Disconnect hose assembly (2). Remove bolts (3).

Remove engine oil filter base (4) and the oil seal.
g01151723
Illustration 39
g01150963
Personal injury can result from being struck by
Illustration 38 parts propelled by a released spring force.
3. Remove engine oil cooler (5). Make sure to wear all necessary protective equip-
ment.
Follow the recommended procedure and use all

recommended tooling to release the spring force.
1. Remove elbow (1) and O-ring seal (3) from engine

oil filter base (6).
2. Remove plug (2) and the O-ring seal from engine

oil filter base (6).
RENR9579-13 23
Engine Book
3. Remove spring (4) and valve (5) from engine oil 2. Apply clean engine oil to the O-ring seal. Install
filter base (6). the O-ring seal on plug (2).
4. Remove plug (9) and the O-ring seal from engine 3. Apply clean engine oil to valve (5). Install valve (5),
oil filter base (6). spring (4), and plug (2) in engine oil filter base (6).
5. Remove spring (8) and valve (7) from engine oil 4. Apply clean engine oil to the O-ring seal. Install
filter base (6). the O-ring seal on plug (9).
5. Apply clean engine oil to valve (7). Install valve (7),

i02300235
spring (8), and plug (9) in engine oil filter base (6).
Engine Oil Filter Base - End By:
Assemble
a. Install the engine oil filter base. Refer to
SMCS Code: 1306-016 Disassembly and Assembly, “Engine Oil Filter
Base and Oil Cooler - Install”.
Assembly Procedure
i02298181
NOTICE
Engine Oil Filter Base and Oil
Cooler - Install
component life. SMCS Code: 1306-012; 1378-012
NOTICE

component life.
g01151723
Illustration 40
Improper assembly of parts that are spring loaded

To prevent possible injury, follow the established

assembly procedure and wear protective equip- Illustration 41
g01150963
ment.
1. Install engine oil cooler (5).
1. Apply clean engine oil to O-ring seal (3). Install
O-ring seal (3) on elbow (3). Install elbow (1) in
engine oil filter base (6).
24 RENR9579-13
Engine Book
i02298281
Engine Oil Pump - Remove

SMCS Code: 1304-011
Removal Procedure
Table 17
Required Tools
A 1P-0510 Driver Gp 1
Start By:
a. Remove the engine oil pan. Refer to Disassembly

and Assembly, “Engine Oil Pan - Remove and
Install”.
Illustration 42
g01150959 NOTICE
2. Apply clean engine oil to the oil seal. Install the oil
seal in engine oil filter base (4). Position engine Contaminants may cause rapid wear and shortened
oil filter base (4) over the engine oil cooler. Install component life.
bolts (3). Connect tube assembly (2).
NOTICE

products.

mandates.
g01150737
Illustration 43
3. Install engine oil filter (1).
4. Fill the engine with oil to the correct level. Refer

to Operation and Maintenance Manual, “Refill
Capacities and Recommendations”.
RENR9579-13 25
Engine Book
g01152433
Illustration 46
g01151740
7. Remove bolt (12) and the washer. Remove idler
Illustration 44 gear (11). Use Tooling (A) in order to remove
bearing (10) from idler gear (11). Remove shaft (9)
1. Remove bolts (1). from engine oil pump (4).
2. Remove bolt (2).
i02300326
3. Remove bolts (3) and remove engine oil pump (4).
Engine Oil Pump - Install
4. Remove the O-ring seal that is located between
the cylinder block and the outlet elbow. SMCS Code: 1304-012
Table 18
Required Tools
NOTICE

component life.
g01152424
Illustration 45
5. Remove bolts (5) and remove outlet elbow (6).
6. Remove bolts (7). Remove oil pickup tube (8) and

the gasket.
26 RENR9579-13
Engine Book
g01152433
Illustration 47
1. Install shaft (9) onto engine oil pump (4). Use g01151740
Tooling (A) and a suitable press in order to install Illustration 49
bearing (10) into idler gear (11). Position idler gear
(11) on shaft (9). Install bolt (12) and the washer. 4. Install the O-ring seal. Position engine oil pump
(4) on the cylinder block.
5. Install bolts (3).
6. Install bolt (2).
End By:
a. Install the engine oil pan. Refer to Disassembly

Install”.
g01152424
Illustration 48
2. Position oil pickup tube (8) and the gasket. Install

bolts (7). Position outlet elbow (6) and install bolts
(5).
Note: Ensure that the mounting surfaces for the

engine oil pump are thoroughly clean.
3. Inspect the condition of the O-ring seal. Replace

the O-ring seal, if necessary.
RENR9579-13 27
Engine Book
i02360470
Water Pump - Remove

SMCS Code: 1361-011
Removal Procedure
Personal injury can result from hot coolant, steam

and alkali.
At operating temperature, engine coolant is hot

and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to

relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to g01151111
touch with your bare hand. Illustration 50
Do not attempt to tighten hose connections when 3. Loosen hose clamps (1).
the coolant is hot, the hose can come off causing
burns. 4. Disconnect hose (2).
Cooling System Coolant Additive contains alkali. 5. Remove bolts (4) and elbow assembly (5).
Avoid contact with skin and eyes.
6. Remove bolts (6).
NOTICE 7. Remove water pump (3) and the gasket.

i02880103
collect the fluid with suitable containers before open- Water Pump - Disassemble
nent containing fluids. SMCS Code: 1361-015
Dealer Service Tool Catalog” for tools and supplies Disassembly Procedure
Table 19
products.
Required Tools
Dispose of all fluids according to local regulations and Part
mandates. Tool Number Part Description Qty
to Operation and Maintenance Manual, “Cooling Start By:
System Coolant (ELC) - Change”.
a. Remove the water pump. Refer to Disassembly
2. Remove the belt. Refer to Operation and and Assembly, “Water Pump - Remove”.
Maintenance Manual, “Belts - Inspect/Replace”.
28 RENR9579-13
Engine Book
NOTICE

component life.
g01156016
Illustration 51
1. Remove O-ring seals (1) and (2).
2. Remove bolts (3). Remove rear cover (4) and

gasket (5).
g01156016
3. Use Tooling (A) and a suitable press in order to Illustration 52
remove impeller (6) from shaft assembly (9).
1. Use Tooling (A) and a suitable press in order
Note: Do not allow the shaft assembly to fall when to install shaft assembly (9) in water pump
the shaft assembly is removed. housing (8). After installation, the bearing on shaft
assembly (9) should be flush with the face of water
4. Use Tooling (A) and a suitable press in order pump housing (8).
to remove shaft assembly (9) from water pump
housing (8). 2. Use Tooling (B) to install seal (7) over shaft
assembly (9) and into water pump housing (8).
5. Use Tooling (A) to remove seal (7) from water
pump housing (8). 3. Use Tooling (A) and a suitable press in order to
install impeller (6) onto shaft assembly (9). Install
impeller (6) until the distance between impeller (6)
i04553969 and the machined surface of water pump housing
(8) is 0.75 ± 0.25 mm (0.030 ± 0.010 inch).
Water Pump - Assemble
4. Position gasket (5) and rear cover (4) on water
SMCS Code: 1361-016 pump housing (8). Install bolts (3).
Assembly Procedure Note: Check the O-ring seals for wear or for damage.
If necessary, replace the O-ring seals.
Table 20
Required Tools 5. Install O-ring seals (1) and (2).
Part End By:
A 1P-0510 Driver Gp 1 a. Install the water pump. Refer to Disassembly and
Assembly, “Water Pump - Install”.
B 183-4028 Seal Driver 1
RENR9579-13 29
Engine Book
i02360471 i02298823
Water Pump - Install Water Temperature Regulator -

SMCS Code: 1361-012
Remove and Install
SMCS Code: 1355-010
Removal Procedure
NOTICE

component life. Personal injury can result from hot coolant, steam
and alkali.
At operating temperature, engine coolant is hot

and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to

relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when

the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.

Avoid contact with skin and eyes.
NOTICE
g01151111
Illustration 53
1. Position the gasket and water pump (3) on the component life.
engine block. Install bolts (6).
NOTICE
2. Position elbow assembly (5). Install bolts (4). Care must be taken to ensure that fluids are contained
3. Connect hose (2). ing, adjusting and repair of the product. Be prepared to
4. Tighten hose clamps (1). ing any compartment or disassembling any compo-
5. Install the belt. Refer to Operation and
Maintenance Manual, “Belts - Inspect/Replace”. Refer to Special Publication, NENG2500, “Caterpillar
6. Fill the cooling system with coolant. Refer to suitable to collect and contain fluids on Caterpillar
Operation and Maintenance Manual, “Cooling products.
System Coolant (ELC) - Change” and Operation
and Maintenance Manual, “Capacities (Refill)”. Dispose of all fluids according to local regulations and
mandates.

to Operation and Maintenance Manual, “Cooling
System Coolant (ELC) - Change”.
30 RENR9579-13
Engine Book
g01151335 g01151685
2. Remove bolts (1) from water temperature 4. Remove seal (5) from water temperature regulator
regulator housing (2). housing (2).
Table 21
Required Tools
Part
Tool Part Number Qty
Description
A 221-8647 Seal Installer 1
NOTICE

component life.
1. Clean the mating surfaces of the water

temperature regulator housings.
g01151337
Illustration 55
3. Remove water temperature regulator housing (2).

Remove gasket (3). Remove water temperature
regulators (4).
RENR9579-13 31
Engine Book
g01151691 g01151335
2. Use Tooling (A) and install seal (5) into water 4. Position water temperature regulator housing (2).
temperature regulator housing (2). Install bolts (1).
5. Fill the cooling system with coolant. Refer to

Operation and Maintenance Manual, “Cooling
and Maintenance Manual, “Capacities (Refill)”.
i03582800
Gear Group (Rear) - Remove

and Install
SMCS Code: 1206-010; 1212-010
Removal Procedure
Table 22
Required Tools
Part
g01151337 A 1P-0520 Driver Gp 1
Illustration 58
B 1P-0510 Driver Gp 1
3. Install water temperature regulators (4). Install a
new gasket (3).
Start By:
a. Remove the flywheel and pump drive gear.

Refer to Disassembly and Assembly, “Flywheel
- Remove”.
NOTICE

component life.
32 RENR9579-13
Engine Book
g01383883 g01384414
1. Remove bolts (1) and remove retainer (2). 5. Use Tooling (B) in order to remove bearing (7)
Remove gear assembly (3). from adapter assembly (6).
g01383924 g01384424
2. Use Tooling (A) in order to remove bushing (4) 6. Remove gear assembly (8).
from gear assembly (3).
3. Repeat Steps 1 and 2 for the opposite side.
g01384430
Illustration 65
7. Remove cover (9) and the O-ring seal.

g01383927
Illustration 62
4. Remove bolts (5). Remove adapter (6) and the

O-ring seal.
RENR9579-13 33
Engine Book
g01384432
Illustration 66
8. Use Tooling (B) in order to remove bearing (10).
9. Repeat Steps 4 through 8 for the opposite side.
Installation Procedure Illustration 69

g01384693
NOTICE 1. Lower the temperature of bearing (10). Be sure to

Keep all parts clean from contaminants. match Dimension (B) and Dimension (C) when
you are installing bearing (10). Dimension (B)
Contaminants may cause rapid wear and shortened indicates the angle of the joint on bearing (10).
component life. Dimension (B) is 15° ± 1°. Dimension (C) shows
the distance from bearing (10) to the end of
the bore. Dimension (C) is 4.000 ± 0.500 mm
(0.1575 ± 0.0197 inch).
g01384432
Illustration 67
g01384714
Illustration 70
g01384692
Illustration 68
34 RENR9579-13
Engine Book
g01384783
Illustration 73
4. Install gear assembly (8). Be sure that oil passage

plug (8A) is facing outward.
g01384715
Illustration 71
2. Lower the temperature of bearing (10A). Be sure

to match Dimension (D) and Dimension (E) when
you are installing bearing (10A). Dimension (D)
indicates the angle of the joint on bearing (10A).
Dimension (D) is 15° ± 1°. Dimension (E) shows
the distance from bearing (10A) to the end of
the bore. Dimension (E) is 4.000 ± 0.500 mm
(0.1575 ± 0.0197 inch).
g01384809
Illustration 74
g01384430
Illustration 72
3. Install the O-ring seal and cover (9).

g01384831
Illustration 75
5. Lower the temperature of bearing (7). Be sure

to match Dimension (F) and Dimension (G)
when you are installing bearing (7) into adapter
assembly (6). Dimension (F) indicates the angle
of the joint on bearing (7). Dimension (F) is 15°
± 1°. Dimension (G) shows the distance from
bearing (7) to the end of the bore. Dimension (G)
is 3.500 ± 0.500 mm (0.1378 ± 0.0197 inch).
RENR9579-13 35
Engine Book
End By:
a. Install the flywheel and pump drive gear. Refer to

Disassembly and Assembly, “Flywheel - Install”.
i04530761
Flywheel - Remove
SMCS Code: 1156-011
Removal Procedure
Table 23
g01383927
Illustration 76 Required Tools
6. Install the O-ring seal and adapter assembly (6). Part

Tool Part Description Qty
Install bolts (5). Number
- Guide Stud
7. Repeat Steps 3 through 6 for the opposite side. A 1
M16 x 2 by 12inch
g01384996
Illustration 77
8. Lower the temperature of bearing (4). Install

bearing (4) into gear assembly (3). Be sure that
each relief (H) in bearing (4) is within 2° of each
relief in gear assembly (3).
g02711645
Illustration 79
1. Remove bolts 180 degrees apart. Install Tooling

(A). Remove the remaining bolts (1).
g01383883
Illustration 78
9. Position gear assembly (3) and retainer (2). Install

bolts (1).
g02711621
10. Repeat Steps 8 and 9 for the opposite side. Illustration 80
36 RENR9579-13
Engine Book
2. Fasten a suitable lifting device to flywheel (2).

The weight of flywheel (2) is approximately 60 kg
(130 lb).
3. Remove flywheel (2).
4. Use a hammer and a punch in order to remove

the flywheel ring gear, if necessary.
5. Remove the pump drive gear, if necessary.
i04531966
Flywheel - Install
SMCS Code: 1156-012
Table 24
Required Tools Illustration 82
g02711645
Part
Tool Number Part Description Qty 4. Position flywheel (2) on Tooling (A).
- Guide Stud 5. Apply Tooling (B) to the threads of bolts (1).

A 1
M16 x 2 by 12inch
B - Loctite 771 - 6. Install bolts (1). Remove Tooling (A) and install
remaining bolts (1). Tighten bolts evenly to a
torque of 300 ± 40 N·m (221 ± 30 lb ft).
1. Install the pump drive gear, if necessary.
7. Check the flywheel runout. Refer to Testing and
2. Raise the temperature of the flywheel ring gear. Adjusting, “Flywheel - Inspect”.
Do not use a torch to heat the flywheel ring gear.
Install the flywheel ring gear on the flywheel.
Position the flywheel ring gear with the part i02271689
number toward the crankshaft. Allow the flywheel
ring gear to cool. Use a soft hammer in order to Crankshaft Rear Seal - Remove
seat the flywheel ring gear against the shoulder
of the flywheel. SMCS Code: 1161-011
Removal Procedure
Start By:
a. Remove the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Remove”.
g02711621
Illustration 81
3. Attach a suitable lifting device to flywheel (2).

The weight of flywheel (2) is approximately 60 kg
(130 lb).
RENR9579-13 37
Engine Book
NOTICE NOTICE
Care must be taken to ensure that fluids are contained Keep all parts clean from contaminants.
ing, adjusting and repair of the product. Be prepared to Contaminants may cause rapid wear and shortened
collect the fluid with suitable containers before open- component life.
Note: Leave the shipping sleeve in place in order to
Refer to Special Publication, NENG2500, “Caterpillar install the crankshaft rear seal. The crankshaft rear
Tools and Shop Products Guide” for tools and supplies seal must be installed dry.
products. Note: The O-ring, the seal group, and the sleeve are
not serviceable separately. If the seal and the wear
Dispose of all fluids according to local regulations and sleeve are separated, these components cannot be
mandates. used again.
g01140085
g01140085 Illustration 84
Illustration 83
1. Use tooling (A) in order to install the crankshaft
1. Remove bolts (2). wear sleeve.
2. Remove crankshaft rear seal (1) from the 2. Lubricate the O-ring seal with clean engine oil.
crankshaft. Position the O-ring seal on the back of crankshaft
rear seal (1).
i03135021
3. Position crankshaft rear seal (1) and the shipping
Crankshaft Rear Seal - Install sleeve over the crankshaft. Push crankshaft rear
seal (1) in place. This will dislodge the shipping
SMCS Code: 1161-012 sleeve.
4. Install new bolts (2). Tighten the bolts to a torque

Installation Procedure of 12 ± 3 N·m (106 ± 27 lb in).
Table 25
End By:
Required Tools
Part a. Install the flywheel. Refer to Disassembly and
Tool Number Part Description Qty Assembly, “Flywheel - Install”.
A 147-2675 Wear Sleeve Installer 1
38 RENR9579-13
Engine Book
i03581480
Flywheel Housing - Remove

and Install
SMCS Code: 1157-010
Removal Procedure
Table 26
Required Tools
Part
g01910077
A 138-7575 Link Bracket 2 Illustration 86
1. Remove bolts (1) and retainer (2). Remove gear

Start By: assembly (3). Repeat for gear assembly (4).
a. Remove the crankshaft rear seal. Refer to 2. Attach Tooling (A) and a suitable lifting device
Disassembly and Assembly, “Crankshaft Rear to flywheel housing (6). The weight of flywheel
Seal - Remove”. housing (6) is approximately 113 kg (250 lb).
b. Remove the electric starting motor. Refer to 3. Remove bolts (5). Use Tooling (A) and the suitable
Disassembly and Assembly, “Electric Starting lifting device in order to remove flywheel housing
Motor - Remove and Install”. (6).
NOTICE
Keep all parts clean from contaminants. Installation Procedure
Table 27
component life. Required Tools
Part
A 138-7575 Link Bracket 2
B 1U-8846 Gasket Sealant 1
NOTICE

component life.
g01910054
Illustration 85
g01910077
Illustration 87
RENR9579-13 39
Engine Book
b. Remove the electric starting motor. Refer to

Disassembly and Assembly, “Electric Starting
Motor - Remove and Install”.
g01910054
Illustration 88
1. Apply Tooling (B) to the entire mounting surface of

flywheel housing (6). Flywheel housing (6) must
be installed within 10 minutes of applying Tooling
(B).
2. Attach Tooling (A) and a suitable lifting device

to flywheel housing (6). The weight of flywheel
housing (6) is approximately 113 kg (250 lb). Use g01151394
Illustration 89
Tooling (A) and the suitable lifting device in order
to position flywheel housing (6) to the engine.
Install bolts (5). 1. Attach Tooling (A) and a suitable lifting device
onto flywheel housing (1). The weight of flywheel
3. Install gear assembly (3). Install retainer (2) and housing (1) is approximately 37 kg (82 lb).
bolts (1). Repeat for gear assembly (4).
2. Remove bolts (2). Remove bolts (3).
End By:
3. Remove bolts (4) (not shown) that fasten the
a. Install the electric starting motor. Refer to engine oil pan to flywheel housing (1). Remove
Disassembly and Assembly, “Electric Starting flywheel housing (1).
b. Install the crankshaft rear seal. Refer to
Disassembly and Assembly, “Crankshaft Rear Table 29
Seal - Install”. Required Tools
i02299056
Flywheel Housing - Remove B 1U-8846 Gasket Sealant 1
and Install
1. Apply Tooling (B) to the entire mounting surface of
SMCS Code: 1157-010 the flywheel housing prior to installation.
Removal Procedure
Table 28
Required Tools
Start By:
a. Remove the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Remove”.
40 RENR9579-13
Engine Book
g01151394 g01151434
2. Attach Tooling (A) and a suitable lifting device 2. Remove bolts (2) from crankshaft vibration
onto flywheel housing (1). The weight of flywheel damper (1). Remove crankshaft vibration damper
housing (1) is approximately 37 kg (82 lb). Position (1) from the crankshaft pulley.
flywheel housing (1) on the engine block.
3. Remove bolts (3). Remove crankshaft pulley (4).
3. Install bolts (2). Install bolts (3).
4. Install bolts (4) (not shown) that fasten the engine

oil pan to flywheel housing (1).
End By:
a. Install the electric starting motor. Refer to

Disassembly and Assembly, “Electric Starting
b. Install the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Install”.
i02299093
Vibration Damper and Pulley -

Remove and Install
SMCS Code: 1205-010
Removal Procedure
g01151434
Illustration 92
1. Remove the belt. Refer to Operation and
Maintenance Manual, “Belts - Inspect/Replace”. 1. Position crankshaft pulley (4) on the crankshaft.
Install bolts (3). Tighten bolts (3) to a torque of
190 ± 30 N·m (140 ± 22 lb ft).
2. Position crankshaft vibration damper (1) on

crankshaft pulley (4). Install bolts (2).

RENR9579-13 41
Engine Book
i02299146 2. Remove bolts (3) and remove engine trunnion (4).

Crankshaft Front Seal -
Remove
SMCS Code: 1160-011
Removal Procedure
Table 30
Required Tools
A 1U-7600 Slide Hammer Puller 1
B 1U-8145 Drill Bit 1
Start By:
a. Remove the vibration damper and the pulley.

Refer to Disassembly and Assembly, “Vibration
Damper and Pulley - Remove and Install”. g01151456
Illustration 95
3. Use Tooling (B) to carefully drill three evenly

spaced holes in crankshaft front seal (5).
4. Alternate between the drilled holes and use

Tooling (A) to remove crankshaft front seal (5).
i02299281
Crankshaft Front Seal - Install

SMCS Code: 1160-012
Illustration 93
g01151453 Installation Procedure
Table 31
1. Remove bolts (1) and remove engine support (2).
Required Tools
C 1U-7430 Front Seal Installer 1
NOTICE

component life.
g01151455
Illustration 94
42 RENR9579-13
Engine Book
g01151453
Illustration 98
3. Position engine support (2) and install bolts (1).
End By:
g01151527 a. Install the vibration damper and the pulley. Refer

Illustration 96
to Disassembly and Assembly, “Vibration Damper
and Pulley - Remove and Install”.
Note: The crankshaft seal is designed to be installed
dry.
i02299333
1. Use Tooling (C) and install crankshaft front seal
(5). Front Cover - Remove
SMCS Code: 1166-011
Removal Procedure
Start By:
a. Remove the vibration damper and the pulley.

Refer to Disassembly and Assembly, “Vibration
Damper and Pulley - Remove and Install”.
b. Remove the fan drive. Refer to Disassembly and

Assembly, “Fan Drive - Remove”.
c. Remove the unit injector hydraulic pump. Refer

NOTICE
g01151455
Illustration 97 ing, adjusting and repair of the product. Be prepared to
2. Position engine trunnion (4) and install bolts (3). ing any compartment or disassembling any compo-
Tighten bolts (3) to a torque of 105 ± 20 N·m nent containing fluids.
(77 ± 15 lb ft).
products.

mandates.
RENR9579-13 43
Engine Book
i02299803
Front Cover - Install

SMCS Code: 1166-012
NOTICE

component life.
Note: The rear face of the cover and the front face of
the housing must be clean.
g01151545
Illustration 99
1. Remove bolts (1) and remove support assembly

(2).
g01151669
Illustration 101
1. Position front cover (5) and the gasket on the

engine.
3. Install bolts (4). Remove the support from the

Illustration 100
g01151669 attachment for the accessory drive.
2. Support the attachment for the accessory drive

and remove bolts (4).
3. Remove bolts (3). Remove front cover (5) and the

gasket.
44 RENR9579-13
Engine Book
NOTICE

products.

mandates.
g01151545
Illustration 102
4. Position support assembly (2) and install bolts (1).
End By:
a. Install the unit injector hydraulic pump. Refer

b. Install the fan drive. Refer to Disassembly and Illustration 103

g01151885
Assembly, “Fan Drive - Install”.
1. Disconnect harness assemblies (1) and (2).
c. Install the vibration damper and the pulley. Refer
to Disassembly and Assembly, “Vibration Damper
and Pulley - Remove and Install”.
i02300425
Housing (Front) - Remove

SMCS Code: 1151-011
Removal Procedure
Start By:
a. Remove the unit injector hydraulic pump. Refer

b. Remove the crankshaft front seal. Refer to

Disassembly and Assembly, “Crankshaft Front
Seal - Remove”.
g01151892
Illustration 104
c. Remove the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Remove”. 2. Remove bolts (5).
4. Remove front housing (4).

RENR9579-13 45
Engine Book
i02300467 6. Install bolts (5).

Housing (Front) - Install
SMCS Code: 1151-012
Table 32
Required Tools
A 138-8440 Component Cleaner 1
B 4C-9500 Quick Cure Primer 1
C 1U-8846 Gasket Sealant 1 g01151885
Illustration 106
NOTICE 7. Connect harness assemblies (1) and (2).

End By:
component life. a. Install the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Install”.
b. Install the crankshaft front seal. Refer to

Disassembly and Assembly, “Crankshaft Front
Seal - Install”.
c. Install the unit injector hydraulic pump. Refer

i02544248
Crankcase Breather - Remove

and Install
SMCS Code: 1317-010
Removal Procedure
NOTICE
Illustration 105
g01151892 Keep all parts clean from contaminants.
1. Clean the joint face on front housing (4) with Contaminants may cause rapid wear and shortened
Tooling (A). component life.
2. Apply Tooling (B) to the joint face.
Note: Do not allow Tooling (C) to seal the main oil

passage on front housing (4).
3. Apply Tooling (C) to the joint face. Spread the

sealant uniformly. Front housing (4) must be
installed within ten minutes of applying the sealant.
4. Position front housing (4) on the cylinder block.

46 RENR9579-13
Engine Book
NOTICE

products.

mandates.
g00952689
Illustration 108
1. Check the condition of the O-ring seal. Replace

the O-ring seal if the O-ring seal is damaged.
2. Install the O-ring seal and breather assembly (3)

on the fumes disposal.
3. Install bolt (1) and the washer. Tighten bolt (1) to a

torque of 15 ± 3 N·m (11 ± 2 lb ft).
4. Install hose assembly (5). Tighten hose clamp (2)

and install bolt (4) in the hold-down bracket.
i02544273
Illustration 107
g00952689 Cylinder Block Cover - Remove
1. Remove bolt (1) and the washer from breather
and Install
assembly (3). SMCS Code: 1201-010-CH
2. Loosen hose clamp (2) and remove bolt (4) from
the hold-down bracket. Remove hose assembly Removal Procedure
(5).
Start By:
3. Remove breather assembly (3) and the O-ring
seal from the fumes disposal. a. Remove the electronic control module. Refer to
Disassembly and Assembly, “Electronic Control
Module - Remove and Install”.
NOTICE

component life.
RENR9579-13 47
Engine Book
NOTICE

products.

mandates.
g01154180
Illustration 110
g01154180
Illustration 109
1. Disconnect tube assembly (1).
3. Remove bolts (2). Remove cylinder block cover g01101767

(3). Remove the O-ring seals and the gasket from Illustration 111
the cylinder block.
Note: Check the condition of the O-ring seals and the
gasket. Replace the O-ring seals and the gasket, if
necessary.
1. Install the O-ring seals and the gasket on the

cylinder block. Position cylinder block cover (3).
2. Install bolts (2). Tighten bolts (2) by using the

following procedure:
a. Tighten the bolts in a numerical sequence.
b. Tighten the bolts again in a numerical

sequence.

48 RENR9579-13
Engine Book
4. Connect tube assembly (1).
End By:
a. Install the electronic control module. Refer to

Disassembly and Assembly, “ Electronic Control
Module - Remove and Install”.
i02580032
Valve Mechanism Cover -

Remove and Install
SMCS Code: 1107-010 g01152102
Illustration 113
Removal Procedure
NOTICE

component life.
g01138382
Illustration 114
1. Position seal (3) in valve mechanism cover (2).

Apply Tooling (A) to both sides of the seal joint.
Position valve mechanism cover (2) and seal (3)
on the valve cover base.
2. Install bolts (1). Tighten bolts (1) in a numerical

g01152102 sequence to a torque of 20 ± 3 N·m (15 ± 2 lb ft).
Illustration 112
1. Remove bolts (1). i02409213
2. Remove valve mechanism cover (2) and seal (3). Valve Mechanism Cover Base -
Remove and Install
SMCS Code: 1120-010
Table 33
Required Tools Removal Procedure
Start By:
A 4C-9612 Silicone Sealant 1
a. Remove the valve mechanism cover. Refer to
NOTICE
Contaminants may cause rapid wear and shortened NOTICE

component life. Keep all parts clean from contaminants.

component life.
RENR9579-13 49
Engine Book
g01140735 g01140735
1. Disconnect sensor (4) and harness assembly (6)

from valve cover base (5).
2. Remove bolt (1) and the clip that holds the

harness assembly.
3. Disconnect harness assemblies (3).
4. Remove bolts (2), the washers, and the springs.
5. Remove valve cover base (5) and the seal.
g01061297
Illustration 117
NOTICE
Keep all parts clean from contaminants. 1. Position the seal and valve cover base (5) on the
cylinder head.
component life. 2. Install the springs, the washers, and bolts (2).
Tighten bolts (2) in a numerical sequence.
3. Connect harness assemblies (3).
4. Install the clip and bolt (1) that holds the harness
assembly.
5. Connect harness assembly (6) to valve cover

base (5). Tighten the bolts to a torque of 6 ± 1 N·m
(53 ± 9 lb in).
6. Connect sensor (4) to valve cover base (5).
End By:

50 RENR9579-13
Engine Book
i02884496 i02544763
Rocker Arm and Shaft - Rocker Arm - Disassemble

Remove SMCS Code: 1123-015
SMCS Code: 1102-011
Removal Procedure Start By:
Start By: a. Remove the rocker arm and shaft. Refer to
Disassembly and Assembly, “Rocker Arm and
a. Remove the valve mechanism cover. Refer to
Shaft - Remove”.
NOTICE
NOTICE
component life.
component life.
Note: Place an identification mark on each of the
components of the rocker shaft for installation
1. Place identification marks on each of the rocker
purposes.
arms in order to identify the proper location for
installation.
g01160012
Illustration 119
g00953116
Illustration 118
2. Loosen nuts (3) and rocker arm adjustment

screws (2). Personal injury can result from being struck by
parts propelled by a released spring force.
3. Remove bolts (1) and rocker shaft (4).
Make sure to wear all necessary protective equip-
4. Remove the pushrods and the valve bridges. ment.
Follow the recommended procedure and use all

recommended tooling to release the spring force.
1. Remove plug (2) from rocker shaft (1).

RENR9579-13 51
Engine Book
2. Remove stand (6), inlet rocker arm (5), spring (4), End By:
and exhaust rocker arm (3) from rocker shaft (1).
a. Install the rocker arm and shaft. Refer to
i02544772
Shaft - Install”.
Rocker Arm - Assemble
i04506590
SMCS Code: 1123-016
Rocker Arm and Shaft - Install
Assembly Procedure SMCS Code: 1102-012
NOTICE
Table 34
component life. Required Tools
Part
1. Lubricate all components of the rocker arm shaft
with clean engine oil. A 8T-2998 Lubricant -
NOTICE

component life.
1. Apply Tooling (A) to both ends of the pushrods.
2. Lubricate the pushrods with clean engine oil.

Install the pushrods and the valve bridges.
g01160012
Illustration 120
Improper assembly of parts that are spring loaded

To prevent possible injury, follow the established

assembly procedure and wear protective equip-
ment.
2. Install exhaust rocker arm (3), spring (4), inlet Illustration 121
g00953116
rocker arm (5), and stand (6) on rocker shaft (1).
3. Position rocker shaft (4) on the cylinder head.
3. Install plug (2) into rocker shaft (1). Install bolts (1).
52 RENR9579-13
Engine Book
NOTICE

products.
g02685496 Dispose of all fluids according to local regulations and

Illustration 122
mandates.
Rocker shaft hold down bolts tightening sequence
4. Tighten bolts (1) in the sequence shown. Tighten 1. Drain the coolant from the cooling system into
bolts (1) to a torque of 100 ± 20 N·m (74 ± 15 lb ft). a suitable container for storage or for disposal.
Refer to Operation and Maintenance Manual,
5. Apply Tooling (A) to each of the bottom faces of “Cooling System Coolant (ELC) - Change”.
the rocker arms.
6. Position rocker arm adjustment screws (2) and

tighten nuts (3). Adjust the valve lash of the rocker
arms. Refer to Testing and Adjusting, “Engine
Valve Lash - Inspect/Adjust”.
End By:

i02308888
Cylinder Head - Remove

SMCS Code: 1100-011
Removal Procedure
g01156402
Illustration 123
Table 35
Required Tools 2. Remove bolts (1) and remove support assembly
Tool Part Number Part Description Qty (2). Disconnect cable assembly (3). Disconnect
tube assembly (4).
Start By:
a. Remove the rocker arm and shaft. Refer to

Shaft - Remove”.
b. Remove the valve mechanism cover base. Refer

to Disassembly and Assembly, “Valve Mechanism
Cover Base - Remove and Install”.
c. Remove the fan drive. Refer to Disassembly and

RENR9579-13 53
Engine Book
i04016406
Cylinder Head - Install

SMCS Code: 1100-012
Table 36
Required Tools
NOTICE

component life.
g01156406
Illustration 124
3. Disconnect harness assemblies (5), (6), and (7).
4. Disconnect tube assembly (8) from the

turbocharger.
5. Disconnect hose assembly (9).
g01156425
Illustration 126
1. Position the gasket on the engine. Attach Tooling

(A) and a suitable lifting device onto cylinder
head (11). The weight of cylinder head (11) is
approximately 181 kg (400 lb). Position cylinder
head (11) on the engine.
g01156425
Illustration 125
Note: Use caution in order not to damage the tips

of the injectors.
7. Attach Tooling (A) and a suitable lifting device onto

cylinder head (11). The weight of cylinder head
(11) is approximately 181 kg (400 lb). Remove
cylinder head (11) and the gasket.
54 RENR9579-13
Engine Book
7. Fill the cooling system with coolant. Refer to

Operation and Maintenance Manual, “Cooling
and Maintenance Manual, “Capacities (Refill)”.
End By:
a. Install the fan drive. Refer to Disassembly and

b. Install the valve mechanism cover base. Refer to

Cover Base - Remove and Install”.
c. Install the rocker arm and shaft. Refer to

Shaft - Install”.
i02549664
g01156406
Lifter Group - Remove and
Illustration 127
Install
2. Apply clean engine oil to the threads of bolts (10)
and under the bolt heads. Install bolts (10). Refer SMCS Code: 1209-010
to Specifications, “Cylinder Head” for the correct
tightening procedure. Removal Procedure
3. Connect hose assembly (9). Table 37
Required Tools
4. Connect tube assembly (8) onto the turbocharger.
Part
5. Connect harness assemblies (5), (6), and (7). Tool Number Part Description Qty
A FT-2730 Hook 1
Start By:
a. Remove the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head - Remove”.
NOTICE

component life.
g01156402
Illustration 128
6. Connect tube assembly (4). Connect cable

assembly (3). Position support assembly (2) and
install bolts (1).
g00953158
Illustration 129
RENR9579-13 55
Engine Book
1. Use Tooling (A) to remove valve lifters (1). b. Remove the front cover. Refer to Disassembly and
Place identification marks on the valve lifters for Assembly, “Front Cover - Remove”.
installation purposes.
NOTICE
Installation Procedure Keep all parts clean from contaminants.
Table 38 Contaminants may cause rapid wear and shortened

Required Tools component life.
Part
Tool Number Part Description Qty 1. Use Tooling (A) to reposition the valve lifters out of
the way of the camshaft.
A FT-2730 Hook 1
B 8T-2998 Lubricant 1 2. Set the No. 1 piston to top center on the
compression stroke. Refer to Testing and
Adjusting, “Finding Top Center Position for No. 1
Piston”.
g00953158
Illustration 130
1. Apply Tooling (B) to valve lifters (1) prior to g01032348

Illustration 131
installation. Use Tooling (A) to install valve lifters
(1) in the original location in the cylinder block.
3. Ensure that the timing marks on camshaft gear (1)
and idler gear (2) are aligned.
End By:
4. Remove bolts (3) and thrust plate (4) from the
a. Install the cylinder head. Refer to Disassembly
cylinder block.
and Assembly, “Cylinder Head - Install”.
i02274059
Camshaft - Remove
SMCS Code: 1210-011
Removal Procedure
Table 39
Required Tools
Part
g01032349
Illustration 132
A FT-2730 Hook 12
NOTICE
Start By: Do not damage the lobes or the bearings when the
camshaft is removed or installed.
a. Remove the rocker arm and the shaft. Refer to
Shaft - Remove”. 5. Remove camshaft (5) from the cylinder block.
56 RENR9579-13
Engine Book
i02283473
Camshaft - Install
SMCS Code: 1210-012
Table 40
Required Tools
Part
A FT-2730 Hook 12
g01032348
B 8T-2998 Lubricant - Illustration 134
NOTICE
NOTICE When installing the camshaft, make sure the num-
Keep all parts clean from contaminants. ber one cylinder is at top center of the compression
stroke with the timing bolt installed in the flywheel. The
Contaminants may cause rapid wear and shortened camshaft timing is very important. The timing mark
component life. on the camshaft drive gear must line up with the tim-
ing mark on the idler gear. Refer to the Specifications
Manual for more information.
2. Ensure that the timing marks on the camshaft gear

(1) and idler gear (2) are aligned.
3. Install thrust plate (4) and bolts (3).
4. The maximum permissible end play for a worn

camshaft is 0.46 mm (0.018 inch). The maximum
permissible end play for a new camshaft is
0.13 ± 0.08 mm (0.005 ± 0.003 inch).
5. Use Tooling (A) to position the valve lifters in the

g01032349 cylinder block.
Illustration 133
6. Calibrate the speed/timing sensor. Refer to

NOTICE Troubleshooting, “Engine Speed/Timing Sensor -
Do not damage the lobes or the bearings when the Calibrate”.
camshaft is removed or installed.
End By:
Note: During the installation of the camshaft, rotate
the camshaft in both directions in order to prevent a. Install the front cover. Refer to Disassembly and
binding in the camshaft bearing bores. Assembly, “Front Cover - Install”.
1. Lubricate the camshaft lobes and the valve lifter b. Install the rocker arm and the shaft. Refer to
bore with a 50/50 mixture of Tooling (B). Apply Disassembly and Assembly, “Rocker Arm and
clean engine oil on the camshaft bearing journals. Shaft - Install”.
Carefully install camshaft (5) in the cylinder block.
RENR9579-13 57
Engine Book
i02408922 i02545687
Camshaft Gear - Remove and Camshaft Bearings - Remove

Install SMCS Code: 1211-011
SMCS Code: 1210-010-GE
Removal Procedure
Removal Procedure Table 41
Start By: Required Tools

Part
a. Remove the camshaft. Refer to Disassembly and Tool Number Part Description Qty
Assembly, “Camshaft - Remove”.
Camshaft Bearing Tool
A 8S-2241 1
Group
1. Wrap the camshaft with a protective covering in
order to prevent damage to the camshaft.
Start By:
a. Remove the camshaft. Refer to Disassembly and

Assembly, “Camshaft - Remove”.
b. Remove the flywheel housing. Refer to

Disassembly and Assembly, “Flywheel Housing-
Remove and Install”.
Note: Note the oil hole orientation in each camshaft

bearing prior to removal for assembly purposes.
NOTICE
g01142107
Illustration 135
component life.
NOTICE
Do not allow the camshaft to fall to the floor when
pressing it from the drive gear. Also make sure that NOTICE
the camshaft lobes do not catch on the press plates. Care must be taken to ensure that fluids are contained
2. Use a suitable press to remove the camshaft from collect the fluid with suitable containers before open-
camshaft gear (1). ing any compartment or disassembling any compo-
Note: The temperature of the camshaft gear must Dealer Service Tool Catalog” for tools and supplies
not exceed 177 °C (350 °F) during installation. suitable to collect and contain fluids on Caterpillar
products.
1. Raise the temperature of the camshaft gear up to
a temperature of 177 °C (350 °F). Dispose of all fluids according to local regulations and
mandates.
2. Align the key in the camshaft with the groove
(keyway) in the camshaft gear.
3. Install the camshaft gear on the end of the

camshaft.
End By:
a. Install the camshaft. Refer to Disassembly and

Assembly, “Camshaft - Install”.
58 RENR9579-13
Engine Book
1. Refer to Illustration 137 for the locations of the

bearings.
(1) Installation Dimension (A) for bearing

(1) .......... 816.5 ± 0.8 mm (32.15 ± 0.03 inch)
(2) Installation Dimension (B) for bearing

(2) .......... 536.5 ± 0.8 mm (21.12 ± 0.03 inch)
(3) Installation Dimension (C) for bearing

(3) ........... 294.5 ± 0.8 mm (11.59 ± 0.03 inch)
(4) Installation Dimension (D) for bearing

(4) ........ 0.50 ± 0.25 mm (0.020 ± 0.010 inch)
g00633159
Illustration 136
1. Use Tooling (A) to remove the camshaft bearings

from the cylinder block.
i02545718
Camshaft Bearings - Install

SMCS Code: 1211-012
Table 42
Required Tools
Part
Camshaft Bearing Tool
A 8S-2241 1
Group
NOTICE

component life. g00884754
Illustration 138
NOTICE 2. Use Tooling (A) to install bearings (1), (2), and

Camshaft bearings must be installed into their correct (3) that are behind the front bearing. Install the
position. Failure to do so will result in engine damage. bearings to the proper depths. Refer to Illustration
137 and refer to Step 1. Orient the bearings so
that oil holes (5) are located at the tops of the
bores and joints (6) are positioned, as shown.
g00884735
Illustration 137
RENR9579-13 59
Engine Book
NOTICE

component life.
NOTICE

products.

mandates.
1. Drain the engine oil into a suitable container

for storage or disposal. Refer to Operation and
Maintenance Manual, “Engine Oil - Change”.
g00884758
Illustration 139
3. Install front bearing (4). Carefully locate oil hole

(8) at the oil gallery. Orient joint (7), as shown.
End By:
a. Install the flywheel housing. Refer to Disassembly

and Assembly, “Flywheel Housing - Remove and
Install”.
b. Install the camshaft. Refer to Disassembly and

Assembly, “Camshaft - Install”. g01153497
Illustration 140
i02303744 2. Remove bolts (2). Remove engine oil pan (1) and
the gasket.
Engine Oil Pan - Remove and
Install Installation Procedure
SMCS Code: 1302-010 Table 43
Required Tools
Removal Procedure Tool Part Number Part Description Qty
A 8C-8422 Sealant 1
Hot oil and components can cause personal in- NOTICE

jury. Keep all parts clean from contaminants.
Do not allow hot oil or components to contact Contaminants may cause rapid wear and shortened
skin. component life.
60 RENR9579-13
Engine Book
i02549523
Cylinder Liner - Remove

SMCS Code: 1216-011
Removal Procedure
Table 44
Required Tools
Part
g01153497
Illustration 141
173-5527(1) Cylinder Pack Puller 1
A
1U-9897(1) Bridge 1
(1) 5P-8665 Cylinder Liner Puller Gp is an optional Tool for
removing the cylinder liner.
Start By:
a. Remove the pistons and connecting rods. Refer

to Disassembly and Assembly, “Pistons and
Connecting Rods - Remove”.
NOTICE
Illustration 142
g00612810 Contaminants may cause rapid wear and shortened
component life.
1. Clean the mating surface of engine oil pan (1) and
the cylinder block. Apply Tooling (A) to four areas
on the sealing surface of the oil pan. The areas
are Marked Location (Y).
2. Place a new gasket and engine oil pan (1) on the

cylinder block.
3. Tighten four Oil Pan Bolts (X).
4. Start with Bolt (Z) and tighten all remaining bolts

(2) in a counterclockwise sequence.
5. Tighten bolts (2) to a torque of 31 ± 1 N·m

(23 ± 1 lb ft).
g01138987
Illustration 143
6. Start again with Bolt (Z) and tighten all remaining
bolts in a counterclockwise sequence. 1. Use Tooling (A) to remove cylinder liners (1).
7. Tighten bolts (2) again to a torque of 31 ± 1 N·m 2. Remove the seals from cylinder liners (1).
(23 ± 1 lb ft).
8. Fill the engine with oil to the correct level. Refer to

Operation and Maintenance Manual, “Engine Oil -
Change” and Operation and Maintenance Manual,
“Capacities (Refill)”.
RENR9579-13 61
Engine Book
i02274286 i03433580
Cylinder Liner - Install Piston Cooling Jets - Remove

SMCS Code: 1216-012
and Install
SMCS Code: 1331-010
Table 45 Removal Procedure
Required Tools Table 46
Part Required Tools
B 2P-8260 Cylinder Liner Installer 1
A 9S-9082 Engine Turning Tool 1
C 5P-3975 Rubber Lubricant 1
Start By:
NOTICE
Keep all parts clean from contaminants. a. Remove the engine oil pan. Refer to Disassembly
Contaminants may cause rapid wear and shortened Install”.
component life.
NOTICE
1. Check the cylinder liner projection. Refer to Keep all parts clean from contaminants.
Testing and Adjusting, “Cylinder Liner Projection
- Inspect”. Contaminants may cause rapid wear and shortened
component life.
g01139009
Illustration 144
g01144041
Illustration 145
2. Apply Tooling (C) to new seal (2). Install new seal
(2) in the machined groove on cylinder liner (1). 1. Use Tooling (A) to rotate the crankshaft in order to
gain access to the piston cooling jet.
3. Lubricate the lower portion of cylinder liner (1) with
clean engine oil. Ensure that the corresponding 2. Remove bolt (1) and remove piston cooling jet (2).
crankshaft throw is at the bottom center. Use
Tooling (B) to install cylinder liner (1). Installation Procedure
End By: Table 47
a. Install the pistons and connecting rods. Refer Required Tools

to Disassembly and Assembly, “Pistons and Tool Part Number Part Description Qty
Connecting Rods - Install”.
A 9S-9082 Engine Turning Tool 1
62 RENR9579-13
Engine Book
Start By:
NOTICE
Keep all parts clean from contaminants. a. Remove the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Remove”.
component life. b. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump
- Remove”.
c. Remove the piston cooling jets. Refer to

Disassembly and Assembly, “Piston Cooling Jets
- Remove and Install”.
NOTICE

component life.
g01144041
Illustration 146
1. Use Tooling (A) to rotate the crankshaft in order to

gain access to the piston cooling jet.
Note: Engine damage may occur if the piston cooling

jet is not installed properly. Install the piston cooling
jet by hand.
2. Position piston cooling jet (2) in the cylinder block.

Ensure that piston cooling jet (2) is flush with the
cylinder block. Install bolt (1). Tighten bolt (1) to a
torque of 28 ± 7 N·m (21 ± 5 lb ft). g01139028
Illustration 147
End By:
a. Install the engine oil pan. Refer to Disassembly

Install”.
i02886266
Pistons and Connecting Rods

- Remove
SMCS Code: 1225-011
g01139029
Illustration 148
Removal Procedure
Table 48
1. Use Tooling (A) to turn the crankshaft until two of
the connecting rod caps are at the bottom center.
Required Tools
Part 2. Inspect connecting rod (3) and connecting rod cap
Tool Number Part Description Qty (1) for the proper identification mark. Connecting
rod (3) and connecting rod cap (1) should have
A 9S-9082 Engine Turning Tool 1 an etched number on the side that is toward the
camshaft. The number should match the cylinder
number. Mark connecting rod (3) and connecting
rod cap (1), if necessary.
RENR9579-13 63
Engine Book
Note: This engine has fractured connecting rods.

Fractured connecting rods must be handled with
care. Use a soft faced hammer in order to tap the
connecting rod cap, if necessary.
3. Loosen connecting rod cap bolts (2). Remove

connecting rod cap bolts (2) and connecting rod
cap (1).
4. Remove the lower half of connecting rod bearing

(5) from connecting rod cap (1).
5. Push the piston and connecting rod (3) away

from the crankshaft. Remove the upper half of
connecting rod bearing (4) from connecting rod
(3).
6. Remove the piston and connecting rod (3) from

the cylinder liner.
i02274346 g01139072
Illustration 149
- Disassemble
SMCS Code: 1225-015
Table 49
Required Tools
Part
A 4C-3601 Piston Ring Expander 1
B 1P-1861 Retaining Ring Pliers 1
Start By:
a. Remove the pistons and connecting rods. Refer

to Disassembly and Assembly, “Pistons and
Connecting Rods - Remove”. g01139074
Illustration 150
NOTICE Note: This engine has fractured connecting rods.

Keep all parts clean from contaminants. Fractured connecting rods must be handled with
care. Use a soft jawed vise to hold the connecting
Contaminants may cause rapid wear and shortened rod when loosening the connecting rod cap bolts.
component life.
1. Use Tooling (B) in order to remove retaining rings
(3) from piston skirt (2).
2. Remove piston pin (4) and separate piston skirt

(2) and piston crown (6) from connecting rod (1).
3. Inspect bearings (7) in the piston crown (6).
4. Use Tooling (A) to remove piston rings (5).

64 RENR9579-13
Engine Book
NOTICE
Verify correct assembly of the pistons and the con-
necting rods. Ensure that the etched numbers on the
rod and the rod cap are in the correct positions. The
etched number on the rod and the rod cap correspond
to the cylinder in which it should be installed.
g01139053
Illustration 151
NOTICE
The connecting rod must be heated for the installation
of the piston pin bearing. Do not use a torch.
5. Raise the temperature of connecting rod (1) along

Length (X). The maximum distance of Length (X)
is 83.0 mm (3.27 inch).
6. Remove old bearing (8) and install new bearing

(8) at the same time.
7. The bearing joint must be within 5 degrees of one g01139074

Illustration 152
of the locations that are indicated by the arrows.
i02274400

- Assemble
SMCS Code: 1225-016
Assembly Procedure
Table 50
Required Tools
Part
A 4C-3601 Piston Ring Expander 1
B 1P-1861 Retaining Ring Pliers 1
NOTICE Illustration 153

g01139072
Note: This engine has fractured connecting rods.
Contaminants may cause rapid wear and shortened Fractured connecting rods must be handled with
component life. care. Use a soft jawed vise to hold the connecting
rod cap bolts.
1. Check the clearance between the ends of piston

rings (5). Refer to Specifications, “Piston and
Rings”.
RENR9579-13 65
Engine Book
2. Install the oil control piston ring with Tooling (A).

The ends of the spring should be rotated 180 NOTICE
degrees from the ring end gap. The joint between the connecting rod and the connect-
ing rod cap is produced by fracturing. The connecting
3. Install the intermediate piston ring with the side rod assembly must be handled with care in order to
marked “UP-2” toward the top of the piston. Use avoid damage to the mating surfaces. The connecting
Tooling (A) to install the ring. rod assembly must be replaced if any damage occurs
to the mating surfaces. New connecting rod assem-
4. Install the top piston ring with the side marked blies come with the connecting rod caps bolted on the
“UP-1” toward the top of the piston. Use Tooling connecting rod.
(A) to install the ring.
Use only a soft jawed vise to hold the connecting
5. Inspect bearings (7) in piston crown (6). The rod assembly when removing the connecting rod cap
piston crown must be replaced if the piston crown bolts. Use only a soft faced hammer to tap the con-
is worn or damaged. necting rod cap when separating the connecting rod
cap from the connecting rod.
6. Position the piston skirt (2) and piston crown (6)
on connecting rod (1). Apply clean engine oil to Failure to use a soft jawed vise and a soft faced ham-
pin (4) and install pin (4). Use Tooling (B) to install mer may result in damage to the connecting rod as-
retaining rings (3). Ensure that retaining rings (3) sembly.
are in the grooves of piston skirt (2).
End By: 1. Apply clean engine oil to the pistons, the piston
rings, and the cylinder bore.
a. Install the pistons and connecting rods. Refer
to Disassembly and Assembly, “Piston and
Connecting Rods - Install”.
i03120985

- Install
SMCS Code: 1225-012
Table 51 g00828435
Illustration 154
Required Tools Typical Example
2. Place Tooling (B) over both fractured ends of the
A 9S-9082 Engine Turning Tool 1 connecting rod.
B - Plastic Cap 2
3. Position the piston rings so that the end gaps are
C 173-5528 Piston Ring Compressor 1 located 120 degrees from each other. Use Tooling
(C) to compress the piston rings.
NOTICE

component life.
66 RENR9579-13
Engine Book
11. Place an index mark on each connecting rod cap

bolt. Tighten each connecting rod cap bolt (2) for
an additional 90 ± 5 degrees (1/4 turn).
12. Use Tooling (A) to rotate the crankshaft in order

to ensure that the crankshaft turns freely.
End By:
a. Install the piston cooling jets. Refer to Disassembly

and Assembly, “Piston Cooling Jets - Remove
and Install”.
b. Install the engine oil pump. Refer to Disassembly

g01139029
and Assembly, “Engine Oil Pump - Install”.
Illustration 155
c. Install the cylinder head. Refer to Disassembly
4. With the crankshaft throw at the bottom center, and Assembly, “Cylinder Head - Install”.
install the piston and connecting rod (3) in
the engine. Ensure that the proper piston and
connecting rod are in the corresponding cylinder i02886516
with the identification mark on the connecting rod
on the side that is toward the camshaft. Connecting Rod Bearings -
Remove
Note: The forged part number on the connecting
rod must be installed toward the flywheel end of the SMCS Code: 1219-011
engine.
5. Line up the piston and connecting rod (3) with Removal Procedure
the crankshaft. Use a soft faced hammer and tap
Table 52
the piston into the cylinder bore until Tooling (C)
comes off of the piston. Required Tools
Part
6. Before connecting rod (3) comes in contact with Tool Number Part Description Qty
the crankshaft, remove Tooling (B) and install the
upper half of connecting rod bearing (4). Ensure A 9S-9082 Engine Turning Tool 1
that the bearing tab engages with the slot in
connecting rod (3). Start By:
7. Apply clean engine oil to the surface of the upper a. Remove the engine oil pump. Refer to
half of connecting rod bearing (4). Use a soft Disassembly and Assembly, “Engine Oil Pump
faced hammer in order to tap the piston into the - Remove”.
cylinder bore while you guide connecting rod (3)
onto the crankshaft.
NOTICE
8. Place the lower half of connecting rod bearing (5)
in corresponding connecting rod cap (1). Ensure
that the bearing tab engages with the groove in
component life.
connecting rod cap (1).
9. Apply clean engine oil to the surface of the

lower half of connecting rod bearing (5). Install
connecting rod cap (1) on connecting rod (3).
Ensure that the number on connecting rod cap
(1) matches the number on connecting rod (3).
Ensure that the numbers are on the same side.
10. Install NEW connecting rod cap bolts (2). Tighten

NEW connecting rod cap bolts (2) to a torque of
50 ± 5 N·m (37 ± 3 lb ft).
RENR9579-13 67
Engine Book
i02886537
Connecting Rod Bearings -

Install
SMCS Code: 1219-012
Table 53
Required Tools
Part
g01139029
Illustration 156 A 9S-9082 Engine Turning Tool 1
1. Use Tooling (A) to turn the crankshaft until the

connecting rod bearing caps are accessible. NOTICE
2. Check connecting rod (3) and connecting rod caps
(1) for identification and for the location. Contaminants may cause rapid wear and shortened
component life.
3. Remove connecting rod cap bolts (2) and
connecting rod cap (1) from connecting rod (3).
Remove the lower half of connecting rod bearing NOTICE
(5) from connecting rod cap (1). The joint between the connecting rod and the connect-
ing rod cap is produced by fracturing. The connecting
Note: This engine has fractured connecting rods. rod assembly must be handled with care in order to
Fractured connecting rods must be handled with avoid damage to the mating surfaces. The connecting
care. Use a soft faced hammer in order to tap the rod assembly must be replaced if any damage occurs
connecting rod cap, if necessary. to the mating surfaces. New connecting rod assem-
blies come with the connecting rod caps bolted on the
Note: Do not place the fractured faces of the connecting rod.
connecting rod cap on any surface. The connecting
rod cap must be laid flat on the side in order Use only a soft faced hammer to tap the connecting
to prevent damage to the fractured faces of the rod cap when separating the connecting rod cap from
connecting rod cap. the connecting rod.
4. Push connecting rod (3) away from the crankshaft. Failure to use a soft faced hammer may result in dam-
Remove the upper half of connecting rod bearing age to the fractured surfaces of the connecting rod as-
(4) from connecting rod (3). sembly.
Note: Do not damage the fractured faces of the 1. Use Tooling (A) to turn the crankshaft until the
connecting rod. Place a suitable protective cap on connecting rod bearing cap is accessible.
the ends of the connecting rod in order to prevent
damage to the fractured faces of the connecting rod.
g01139029
Illustration 157
68 RENR9579-13
Engine Book
Note: Install the connecting rod bearings dry when i02304108

clearance checks are performed. Apply clean engine
oil to the connecting rod bearings for final assembly. Crankshaft Main Bearings -
Remove
2. Remove the protective caps from the end of
the connecting rod and install the upper half SMCS Code: 1203-011
of connecting rod bearing (4). Ensure that the
bearing tab engages with the slot in connecting
rod (3). Removal Procedure
Table 54
3. Pull the piston and connecting rod assembly onto
the crankshaft. Required Tools
Part
4. Install the lower half of connecting rod bearing Tool Number Part Description Qty
(5) into connecting rod cap (1). Ensure that the
bearing tab engages with the slot in connecting A 2P-5518 Bearing Tool 1
rod cap (1).
Start By:
Note: Do not place the fractured faces of the
connecting rod cap on any surface. The connecting a. Remove the engine oil pump. Refer to
rod cap must be laid flat on the side in order Disassembly and Assembly, “Engine Oil Pump
to prevent damage to the fractured faces of the - Remove”.
connecting rod cap.
Note: Ensure that the number on the connecting NOTICE

rod cap matches the number on the connecting rod.
Make sure that both of the numbers are located on
the same side. Contaminants may cause rapid wear and shortened
component life.
5. Install connecting rod cap (1) and connecting rod
cap bolts (2).
6. Check the bearing clearance. Refer to

Disassembly and Assembly, “Bearing Clearance -
Check”.
7. Tighten connecting rod cap bolts (2) to a torque of

50 ± 5 N·m (37 ± 3 lb ft).
8. Place an index mark on each connecting rod cap

bolt (2). Tighten each bolt for an additional 90 ± 5
degrees (1/4 turn). Illustration 158
g01153704
9. Use Tooling (A) to rotate the crankshaft in order to 1. Remove bolts (1) and crankshaft main bearing
ensure that the crankshaft turns freely. cap (2).
End By: 2. Remove the lower half of the crankshaft main
bearing from crankshaft main bearing cap (2).
a. Install the engine oil pump. Refer to Disassembly
and Assembly, “Engine Oil Pump - Install”.
NOTICE
If the crankshaft is turned in the wrong direction, the
tab of the crankshaft main bearing will be pushed be-
tween the crankshaft and the cylinder block. this can
cause damage to either or both the crankshaft and the
cylinder block.
3. Install Tooling (A) in the crankshaft journal.
4. Turn the crankshaft in order to remove the upper

half of the crankshaft main bearing.
RENR9579-13 69
Engine Book
i02408967 3. Place crankshaft main bearing caps (2) in position

on the cylinder block. Place clean engine oil or
Crankshaft Main Bearings - Molylube on the bolt threads and the washer face.
Install Install bolts (1).
SMCS Code: 1203-012 4. Tighten each bolt (1) to a torque of 95 ± 5 N·m

(70 ± 4 lb ft). Tighten each bolt (1) for an additional
90 ± 5 degrees (1/4 turn).
5. Check the end play of the crankshaft with Tooling
Table 55
(B). The end play must be 0.21 - 0.60 mm
Required Tools (0.008 - 0.024 inch).
Part
Tool Number Part Description Qty End By:
A 2P-5518 Bearing Tool 1 a. Install the engine oil pump. Refer to Disassembly
B 8T-5096 Dial Indicator Group 1 and Assembly, “Engine Oil Pump - Install”.
i02274621
NOTICE
Keep all parts clean from contaminants. Crankshaft - Remove
Contaminants may cause rapid wear and shortened SMCS Code: 1202-011
component life.
Removal Procedure
Note: Place clean engine oil on the crankshaft main
bearings prior to assembly. Ensure that the tabs on Table 56
the back side of the crankshaft main bearings fit in Required Tools
the grooves of the crankshaft main bearing caps and
the cylinder block. Part
Start By:
a. Remove the front housing. Refer to Disassembly

and Assembly, “Housing (Front) - Remove”.
b. Remove the flywheel housing. Refer to

Disassembly and Assembly, “Flywheel Housing
- Remove and Install”.
g01153704
Illustration 159
c. Remove the engine oil pump. Refer to
Disassembly and Assembly, “Engine Oil Pump
1. Use Tooling (A) and install the upper halves of the - Remove”.
crankshaft main bearings in the cylinder block.
Do not put oil on the back of the crankshaft main
bearing. NOTICE
2. Install the lower halves of the crankshaft main
bearings in crankshaft main bearing caps (2). Do Contaminants may cause rapid wear and shortened
not put oil on the back of the crankshaft main component life.
bearing.
1. Ensure that the No. 1 cylinder is at the top
NOTICE center compression stroke. Refer to Testing and
Crankshaft main bearing caps should be installed Adjusting, “Finding Top Center Position for No. 1
with the part number toward the front of the engine. Piston”.
Crankshaft main bearing caps are to be identified by
stamped numbers 1 through 7 that are located on the
bottom surface of the bearing cap. The thrust plate is
used on the number 6 main bearing.
70 RENR9579-13
Engine Book
i02274650
Crankshaft - Install
SMCS Code: 1202-012
Table 57
Required Tools
Part
NOTICE

component life.
g00964659
Illustration 160
2. Remove connecting rod caps (1) and crankshaft NOTICE

main bearing caps (2). Ensure that the crankshaft main bearing tabs engage
with the grooves in the block and the crankshaft main
3. Remove the thrust plates from the cylinder block. bearing cap.
g00953328 g00953328
4. Fasten Tooling (A) and a suitable lifting device 1. Fasten Tooling (A) and a suitable lifting device
to crankshaft (3). The weight of crankshaft (3) is to crankshaft (3). The weight of crankshaft (3)
approximately 79 kg (175 lb). is approximately 79 kg (175 lb). Align the timing
marks and position crankshaft (3) in the cylinder
5. Remove crankshaft (3). block.
2. Apply clean engine oil to the thrust plates and

install the thrust plates in the cylinder block.
RENR9579-13 71
Engine Book
i02717761
Bearing Clearance - Check

SMCS Code: 1203-535; 1219-535
Measurement Procedure
Table 58
Required Tools
Part
198-9142 Plastic Gauge (Green)
0.025 to 0.076 mm 1
(0.001 to 0.003 inch)
198-9143 Plastic Gauge (Red)
0.051 to 0.152 mm 1
(0.002 to 0.006 inch)
A
198-9144 Plastic Gauge (Blue)
Illustration 163
g00964659 0.102 to 0.229 mm 1
(0.004 to 0.009 inch)
3. Install connecting rod caps (1) and crankshaft 198-9145 Plastic Gauge (Yellow)
main bearing caps (2). 0.230 to 0.510 mm 1
(0.009 to 0.020 inch)
4. Tighten the bolts for connecting rod caps (1) by
using the following procedure: Note: Plastic gauge may not be necessary when the
engine is in the chassis.
a. Tighten each bolt to a torque of 50 ± 5 N·m
(37 ± 3 lb ft).
NOTICE
b. Place an index mark on each bolt. Tighten each Keep all parts clean from contaminants.
bolt for an additional 90 ± 5 degrees (1/4 turn).
5. Tighten the bolts for crankshaft main bearing caps component life.
(2) by using the following procedure:
Note: Caterpillar does not recommend the checking
a. Tighten each bolt to a torque of 95 ± 5 N·m of the actual bearing clearances particularly on
(70 ± 4 lb ft). small engines. This is because of the possibility of
obtaining inaccurate results and the possibility of
b. Place an index mark on each bolt. Tighten each damaging the bearing or the journal surfaces. Each
bolt for an additional 90 ± 5 degrees (1/4 turn). Caterpillar engine bearing is quality checked for
specific wall thickness.
End By:
Note: The measurements should be within
a. Install the engine oil pump. Refer to Disassembly specifications and the correct bearings should
and Assembly, “Engine Oil Pump - Install”. be used. If the crankshaft journals and the bores
for the block and the rods were measured during
b. Install the flywheel housing. Refer to Disassembly disassembly, no further checks are necessary.
and Assembly, “Flywheel Housing - Remove and However, if the technician still wants to measure the
Install”. bearing clearances, Tooling (A) is an acceptable
method. Tooling (A) is less accurate on journals with
c. Install the front housing. Refer to Disassembly and small diameters if clearances are less than 0.10 mm
Assembly, “Housing (Front) - Install”. (0.004 inch).
NOTICE
Lead wire, shim stock or a dial bore gauge can dam-
age the bearing surfaces.
72 RENR9579-13
Engine Book
The technician must be very careful to use Tooling (A) Note: When Tooling (A) is used, the readings can
correctly. The following points must be remembered: sometimes be unclear. For example, all parts of
Tooling (A) are not the same width. Measure the
• Ensure that the backs of the bearings and the major width in order to ensure that the parts are
bores are clean and dry. within the specification range. Refer to Specifications
Manual, “Connecting Rod Bearing Journal” and
• Ensure that the bearing locking tabs are properly Specifications Manual, “Main Bearing Journal” for the
seated in the tab grooves. correct clearances.
• The crankshaft must be free of oil at the contact i02304769

points of Tooling (A).
1. Put a piece of Tooling (A) on the crown of the

Atmospheric Pressure Sensor
bearing that is in the cap. - Remove and Install
Note: Do not allow Tooling (A) to extend over the SMCS Code: 1923-010
edge of the bearing.
NOTICE
2. Use the correct torque-turn specifications in order Keep all parts clean from contaminants.
to install the bearing cap. Do not use an impact
wrench. Be careful not to dislodge the bearing Contaminants may cause rapid wear and shortened
when the cap is installed. component life.
Note: Do not turn the crankshaft when Tooling (A)

is installed.
3. Carefully remove the cap, but do not remove

Tooling (A). Measure the width of Tooling (A)
while Tooling (A) is in the bearing cap or on the
crankshaft journal. Refer to Illustration 164.
g01154251
Illustration 165
1. Disconnect harness assembly (1) from

atmospheric pressure sensor (2).
g01152855 2. Remove atmospheric pressure sensor (2) and the

Illustration 164
O-ring seal.
Typical Example
4. Remove all of Tooling (A) before you install the Installation Procedure
bearing cap.
NOTICE

component life.
RENR9579-13 73
Engine Book
1. Drain the coolant into a suitable container for

storage or for disposal. Drain the coolant to a level
that is below the coolant temperature sensor.
Refer to Operation and maintenance Manual,
“Cooling System Coolant (ELC) - Change”.
g01154251
Illustration 166
Note: Check the O-ring seal for wear or for damage.

If necessary, replace the O-ring seal.
1. Install the O-ring seal onto atmospheric pressure Illustration 167

g01156590
sensor (2).
2. Disconnect harness assembly (1) from coolant
2. Install atmospheric pressure sensor (2) and the temperature sensor (2).
O-ring seal. Tighten atmospheric pressure sensor
(2) to a torque of 10 ± 2 N·m (88 ± 18 lb in). 3. Remove coolant temperature sensor (2) from the
engine.
3. Connect harness assembly (1) to atmospheric
pressure sensor (2).
i02309130
Coolant Temperature Sensor -

Remove and Install
SMCS Code: 1906-010
Removal Procedure
NOTICE

suitable to collect and contain fluids on Caterpillar Illustration 168
g01156590
products.
1. Install coolant temperature sensor (2) into the
Dispose of all fluids according to local regulations and engine. Tighten coolant temperature sensor (2) to
mandates. a torque of 20 ± 5 N·m (15 ± 4 lb ft).
74 RENR9579-13
Engine Book
2. Connect harness assembly (1) onto coolant 2. Remove engine oil pressure sensor (2) and the
temperature sensor (2). O-ring seal.
3. Fill the cooling system. Refer to Operation and

maintenance Manual, “Cooling System Coolant
(ELC) - Change”.
NOTICE
i02304779
Engine Oil Pressure Sensor - component life.
Remove and Install
SMCS Code: 1924-010
NOTICE

component life.
NOTICE

suitable to collect and contain fluids on Caterpillar g01154259
Illustration 170
products.
Dispose of all fluids according to local regulations and Note: Check the O-ring seal for wear or for damage.
mandates. If necessary, replace the O-ring seal.
1. Install the O-ring seal on engine oil pressure

sensor (2).
2. Install engine oil pressure sensor (2). Tighten

engine oil pressure sensor (2) to a torque of
10 ± 2 N·m (88 ± 18 lb in).
3. Connect harness assembly (1) onto engine oil

g01154259
Illustration 169
1. Disconnect harness assembly (1) from engine oil

RENR9579-13 75
Engine Book
i02319663 Installation Procedure

Injection Actuation Pressure NOTICE
Sensor - Remove and Install Keep all parts clean from contaminants.
SMCS Code: 1925-010 Contaminants may cause rapid wear and shortened
component life.
Removal Procedure
NOTICE

component life.
NOTICE

products.
g01159711
Illustration 172
mandates. 1. Install injection actuation pressure sensor (1).
Tighten injection actuation pressure sensor (1) to
a torque of 20 ± 2 N·m (15 ± 1 lb ft).
g01159711
Illustration 171
2. Remove injection actuation pressure sensor (1).

76 RENR9579-13
Engine Book
i02304805 Installation Procedure

Speed/Timing Sensor - Table 59
Remove and Install Required Tools

Part
SMCS Code: 1907-010; 1912-010 Tool Number Part Description Qty
A 5P-3975 Rubber Lubricant 1
Removal Procedure
NOTICE

component life.
g01154273
Illustration 173
1. Disconnect harness assemblies (2) from

speed/timing sensors (1).
g01154272
Illustration 175
Note: Check the O-ring seals for wear or for damage.

If necessary, replace the O-ring seals.
1. Apply Tooling (A) to the O-ring seals prior to

installation. Install speed/timing sensors (1).
2. Position bracket (4) and install bolt (3). Tighten

bolt (3) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
g01154272
Illustration 174
2. Remove bolt (3) and bracket (4). Remove

speed/timing sensors (1). Remove the O-ring
seals from speed/timing sensors (1).
RENR9579-13 77
Engine Book
g01154273 g01154343
3. Connect harness assemblies (2) onto speed/timing 1. Disconnect harness assembly (1) from
sensors (1). turbocharger outlet pressure sensor (2).
2. Remove turbocharger outlet pressure sensor (2)

i02304923
and the O-ring seal.
Turbocharger Outlet Pressure
Sensor - Remove and Install
SMCS Code: 1917-010
Removal Procedure
NOTICE

component life.
NOTICE
Refer to Special Publication, NENG2500, “Caterpillar Illustration 178

g01154343
suitable to collect and contain fluids on Caterpillar Note: Check the O-ring seal for wear or damage. If
products. necessary, replace the O-ring seal.
Dispose of all fluids according to local regulations and 1. Install the O-ring seal on turbocharger outlet
mandates. pressure sensor (2).
2. Install turbocharger outlet pressure sensor (2).

Tighten turbocharger outlet pressure sensor (2) to
a torque of 10 ± 2 N·m (88 ± 18 lb in).
78 RENR9579-13
Engine Book
3. Connect harness assembly (1) to turbocharger Installation Procedure

outlet pressure sensor (2).
i02304937
Inlet Air Temperature Sensor -

Remove and Install
SMCS Code: 1921-010
NOTICE

component life.
g01154354
Illustration 180
Note: Check the O-ring seal for wear or for damage.

If necessary, replace the O-ring seal.
1. Install the O-ring seal onto inlet air temperature

sensor (2).
2. Install inlet air temperature sensor (2). Tighten

inlet air temperature sensor (2) to a torque of
20 ± 5 N·m (15 ± 4 lb ft).
3. Connect harness assembly (1) onto inlet air

temperature sensor (2).
g01154354 i02309146
Illustration 179
1. Disconnect harness assembly (1) from inlet air Fan Drive - Remove
temperature sensor (2).
SMCS Code: 1359-011
2. Remove inlet air temperature sensor (2). Remove
the O-ring seal from inlet air temperature sensor Removal Procedure
(2).
1. Remove the belt. Refer to Operation and
RENR9579-13 79
Engine Book
i02310314
Fan Drive - Disassemble

SMCS Code: 1359-015
Table 60
Required Tools
Start By:
a. Remove the fan drive. Refer to Disassembly and

NOTICE
g01156610
Illustration 181 Keep all parts clean from contaminants.
2. Remove bolts (1) and remove pulley (2). Contaminants may cause rapid wear and shortened
component life.
g01156611
Illustration 182
g01157178
Illustration 183
3. Remove bolts (3) and remove fan drive (4).
1. Remove cap (10).
2. Remove bolt (9) and the washer.
3. Remove bearing cone (8) and spacer (7) from fan

drive hub (6).
4. Remove fan drive hub (6) from shaft assembly (1).
5. Remove seal (3), spacer (4), and bearing cone (5)

from fan drive hub (6).
6. Remove pin (2) from shaft assembly (1).

80 RENR9579-13
Engine Book
7. If necessary, use Tooling (A) and remove the

bearing cups from fan drive hub (6).
g01157241
Illustration 185
Illustration 184
g01157216 1. Use a suitable press and install the shaft into the
support.
8. Position shaft assembly (1) into a suitable press.
Use the suitable press and remove the shaft from
the support.
i02310461
Fan Drive - Assemble

SMCS Code: 1359-016
Assembly Procedure
Table 61
Required Tools
B 8T-1807 Bearing Lubricant 1
g01157178
NOTICE Illustration 186
2. Install pin (2) into shaft assembly (1).
component life. 3. Use Tooling (A) and install the bearing cups into
fan drive hub (6).
4. Apply Tooling (B) to the inside of fan drive hub (6).
5. Pack bearing cones (5) and (8) with Tooling (B).
6. Install bearing cone (5) and spacer (4) into fan

drive hub (6).
7. Use Tooling (A) and install seal (3) into fan drive
hub (6).
RENR9579-13 81
Engine Book
8. Install shaft assembly (1) into fan drive hub (6).
9. Install spacer (7) and bearing cone (8).
10. Install bolt (9) and the washer. Tighten bolt (9) to
a torque of 115 ± 5 N·m (85 ± 4 lb ft).
11. Install cap (10).
End By:
a. Install the fan drive. Refer to Disassembly and

i02310299
Fan Drive - Install

SMCS Code: 1359-012
Installation Procedure Illustration 188

g01156610
2. Position pulley (2) and install bolts (1).

i02304424
Electronic Control Module -

Remove and Install
SMCS Code: 1901-010
Removal Procedure
g01156611
Illustration 187
1. Position fan drive (4) and install bolts (3).
g01153932
Illustration 189
82 RENR9579-13
Engine Book
1. Loosen allen head screw (2) until harness i03904991

assembly (1) can be disconnected. Disconnect
harness assembly (1). Electric Starting Motor -
Remove and Install
2. Disconnect hose assemblies (4) and (5).
SMCS Code: 1453-010
3. Remove bolts (6), the washers, and the spacers.
Remove electronic control module (3).
Removal Procedure
Personal injury can result from failure to discon-

nect the battery.
First, disconnect the negative battery cable. Then,

disconnect the positive battery cable.
A positive power lead can cause sparks if the bat-

tery is not disconnected. Sparks can possibly re-
sult in battery explosion or fire.
g01153932
Illustration 190
1. Position electronic control module (3) onto the

cylinder block. Install bolts (6), the washers, and
the spacers. g02146813
Illustration 191
2. Connect hose assemblies (4) and (5).
1. Disconnect cable strap (1).
3. Connect harness assembly (1). Tighten allen head
screw (2). 2. Place an index mark on all of the harness
assemblies. Disconnect the harness assemblies
from electric starting motor (2).
3. Fasten a suitable lifting device to electric starting

motor (4). The weight of electric starting motor (4)
is approximately 35 kg (77 lb).
5. Remove electric starting motor (4) and the gasket

from the flywheel housing.
1. Install electric starting motor (4) in reverse order.
RENR9579-13 83
Engine Book
Index Section
Index
A Cylinder Head - Install ........................................... 53
Installation Procedure ........................................ 53
Air Inlet Heater - Install .......................................... 17 Cylinder Head - Remove ....................................... 52
Installation Procedure ........................................ 17 Removal Procedure ........................................... 52
Air Inlet Heater - Remove ...................................... 16 Cylinder Liner - Install............................................ 61
Removal Procedure ........................................... 16 Installation Procedure ........................................ 61
Atmospheric Pressure Sensor - Remove and Cylinder Liner - Remove........................................ 60
Install ................................................................... 72 Removal Procedure ........................................... 60
D
B
Disassembly and Assembly Section........................ 4
Bearing Clearance - Check ................................... 71
Measurement Procedure ................................... 71
E
C Electric Starting Motor - Remove and Install ......... 82

Camshaft - Install................................................... 56 Removal Procedure ........................................... 82
Installation Procedure ........................................ 56 Electronic Control Module - Remove and Install ... 81
Camshaft - Remove............................................... 55 Installation Procedure ........................................ 82
Removal Procedure ........................................... 55 Removal Procedure ........................................... 81
Camshaft Bearings - Install ................................... 58 Engine Oil Filter Base - Assemble......................... 23
Installation Procedure ........................................ 58 Assembly Procedure.......................................... 23
Camshaft Bearings - Remove ............................... 57 Engine Oil Filter Base - Disassemble .................... 22
Removal Procedure ........................................... 57 Disassembly Procedure ..................................... 22
Camshaft Gear - Remove and Install .................... 57 Engine Oil Filter Base and Oil Cooler - Install ....... 23
Installation Procedure ........................................ 57 Installation Procedure ........................................ 23
Removal Procedure ........................................... 57 Engine Oil Filter Base and Oil Cooler - Remove ... 21
Connecting Rod Bearings - Install ......................... 67 Removal Procedure ........................................... 21
Installation Procedure ........................................ 67 Engine Oil Pan - Remove and Install..................... 59
Connecting Rod Bearings - Remove ..................... 66 Installation Procedure ........................................ 59
Coolant Temperature Sensor - Remove and Engine Oil Pressure Sensor - Remove and Install.. 74
Install ................................................................... 73 Installation Procedure ........................................ 74
Installation Procedure ........................................ 73 Engine Oil Pump - Install ....................................... 25
Crankcase Breather - Remove and Install............. 45 Engine Oil Pump - Remove ................................... 24
Removal Procedure ........................................... 45 Exhaust Manifold - Remove and Install ................. 15
Crankshaft - Install................................................. 70 Installation Procedure ........................................ 15
Crankshaft - Remove............................................. 69
Removal Procedure ........................................... 69
Crankshaft Front Seal - Install ............................... 41 F
Crankshaft Front Seal - Remove ........................... 41 Fan Drive - Assemble ............................................ 80
Removal Procedure ........................................... 41 Assembly Procedure.......................................... 80
Crankshaft Main Bearings - Install......................... 69 Fan Drive - Disassemble ....................................... 79
Installation Procedure ........................................ 69 Disassembly Procedure ..................................... 79
Crankshaft Main Bearings - Remove..................... 68 Fan Drive - Install .................................................. 81
Crankshaft Rear Seal - Install................................ 37 Fan Drive - Remove .............................................. 78
Crankshaft Rear Seal - Remove............................ 36 Flywheel - Install.................................................... 36
Cylinder Block Cover - Remove and Install ........... 46 Flywheel - Remove................................................ 35
84 RENR9579-13
Engine Book
Index Section
Flywheel Housing - Remove and Install .......... 38–39 P

Installation Procedure .................................. 38–39
Removal Procedure ..................................... 38–39 Piston Cooling Jets - Remove and Install.............. 61
Front Cover - Install ............................................... 43 Installation Procedure ........................................ 61
Front Cover - Remove ........................................... 42 Pistons and Connecting Rods - Assemble ............ 64
Removal Procedure ........................................... 42 Assembly Procedure.......................................... 64
Fuel Filter Base - Remove and Install ..................... 4 Pistons and Connecting Rods - Disassemble ....... 63
Installation Procedure .......................................... 5 Disassembly Procedure ..................................... 63
Removal Procedure ............................................. 4 Pistons and Connecting Rods - Install................... 65
Fuel Transfer Pump - Remove and Install............... 5 Installation Procedure ........................................ 65
Installation Procedure .......................................... 6 Pistons and Connecting Rods - Remove............... 62
Removal Procedure ............................................. 5 Removal Procedure ........................................... 62
G R
Gear Group (Rear) - Remove and Install .............. 31 Rocker Arm - Assemble......................................... 51
Installation Procedure ........................................ 33 Assembly Procedure.......................................... 51
Removal Procedure ........................................... 31 Rocker Arm - Disassemble.................................... 50
Disassembly Procedure ..................................... 50
Rocker Arm and Shaft - Install............................... 51
H Installation Procedure ........................................ 51
Rocker Arm and Shaft - Remove........................... 50
Housing (Front) - Install ......................................... 45 Removal Procedure ........................................... 50
Housing (Front) - Remove ..................................... 44
Removal Procedure ........................................... 44 S
Speed/Timing Sensor - Remove and Install .......... 76

I Installation Procedure ........................................ 76
Important Safety Information ................................... 2
Injection Actuation Pressure Sensor - Remove and
Install ................................................................... 75 T
Removal Procedure ........................................... 75 Table of Contents..................................................... 3
Inlet Air Temperature Sensor - Remove and Turbocharger - Install ............................................ 14
Install ................................................................... 78 Installation Procedure ........................................ 14
Installation Procedure ........................................ 78 Turbocharger - Remove ........................................ 14
Inlet and Exhaust Valve Guides - Remove and Removal Procedure ........................................... 14
Install ................................................................... 19 Turbocharger Outlet Pressure Sensor - Remove and
Installation Procedure ........................................ 20 Install ................................................................... 77
Inlet and Exhaust Valve Seat Inserts - Remove and
Install ................................................................... 20
Installation Procedure ........................................ 21 U
Inlet and Exhaust Valves - Remove and Install ..... 18 Unit Injector - Install................................................. 8
Installation Procedure ........................................ 18 Installation Procedure .......................................... 8
Removal Procedure ........................................... 18 Unit Injector - Remove............................................. 7
Removal Procedure ............................................. 7
Unit Injector Hydraulic Pump - Install .................... 13
L Installation Procedure ........................................ 13
Unit Injector Hydraulic Pump - Remove ................ 12
Lifter Group - Remove and Install.......................... 54 Removal Procedure ........................................... 12
Installation Procedure ........................................ 55 Unit Injector Sleeve - Install.................................... 11
Removal Procedure ........................................... 54 Installation Procedure ......................................... 11
Unit Injector Sleeve - Remove............................... 10
RENR9579-13 85
Engine Book
Index Section
Valve Mechanism Cover - Remove and Install...... 48

Valve Mechanism Cover Base - Remove and
Install ................................................................... 48
Vibration Damper and Pulley - Remove and
Install ................................................................... 40
Water Pump - Assemble........................................ 28

Assembly Procedure.......................................... 28
Water Pump - Disassemble ................................... 27
Disassembly Procedure ..................................... 27
Water Pump - Install .............................................. 29
Water Pump - Remove .......................................... 27
Water Temperature Regulator - Remove and
Install ................................................................... 29
86 RENR9579-13
Engine Book
Index Section
RENR9579-13 87
Engine Book
Index Section
©2012 Caterpillar Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge
All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.

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RENR9579-13

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Camshaft - Remove .............................................. 55

Disassembly and Assembly

Fuel Filter Base - Remove and

Refer to Special Publication, NENG2500, “Caterpillar

Dispose of all fluids according to local regulations and

Note: Plug all hose assemblies and all tube

3. Disconnect tube assemblies (4) and (5).

4. Disconnect harness assemblies (6) and (7).

5. Remove bolts (3) and remove fuel filter base (2).

Installation Procedure i03012021

Fuel Transfer Pump - Remove

a. Remove the unit injector hydraulic pump. Refer

Refer to Special Publication, NENG2500, “Caterpillar

Dispose of all fluids according to local regulations and

Contaminants may cause rapid wear and shortened

Note: Tooling (A) is required for replacement of the

4. Install fuel filter (1) onto fuel filter base (2).

Contaminants may cause rapid wear and shortened

1. Thoroughly clean the components and the mating

1. Disconnect tube assemblies (1).

2. Remove bolt (3) that is located at the top left

3. Install Tooling (A) in the top left corner of the pump.

7. Tighten bolts (3) evenly to a torque of 28 ± 2 N·m

a. Install the unit injector hydraulic pump. Refer

Unit Injector - Remove

a. Remove the valve mechanism cover. Refer to g01148880

Refer to Special Publication, NENG2500, “Caterpillar

Dispose of all fluids according to local regulations and

Contaminants may cause rapid wear and shortened

1. Remove the plug at the rear of the cylinder head. g01160779

Note: Do not use a wire brush on the tip of the unit

Unit Injector - Install

G Clear Plastic Tubing

J 4C-6161 Tube Brush 1

Contaminants may cause rapid wear and shortened

1. Evacuate as much fuel and oil as possible from

Note: Tooling (L) is available to clean loose material

2. Inspect the unit injector sleeve for damage and

3. Clean the carbon from the sleeve, the sleeve bore

Note: Using power tools in order to rotate the material

The following procedure is the preferred method

Place a 38 mm (1.5 inch) square piece of Scotch

The surface should be cleaned until the surface is

Note: Do not hit or strike the unit injector during

Unit Injector Sleeve - Remove

a. Remove the unit injectors. Refer to Disassembly

Contaminants may cause rapid wear and shortened

1. Drain the coolant from the cooling system into a

5. Position unit injector sleeve (1) in the cylinder

Note: Allow Tooling (G) to cure for two hours at 21 °C

6. Fill the cooling system with coolant to the correct

a. Install the unit injectors. Refer to Disassembly and

Unit Injector Hydraulic Pump -